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— ABB MEASUREMENT & ANALY TICS | DATA SHEET

Advance Optima AO2000 Series Continuous gas analyzers

2 AO2000 CONTINUOUS GAS ANALYZERS | DS/AO2000-EN REV. B

— Measurement made easy Modular continuous gas analyzers

— A wide variety of measurement technology Analyzer modules for all process and emission monitoring applications

Up to four analyzer modules handling a total of six sample components

“Safety concept” for measuring flammable gases in Zone 2 and for measuring corrosive and toxic gases

Performance-tested for emission monitoring according to EN 15267

— Straightforward handling Common controls, common connection technology Automatic calibration with air or integral calibration cells eliminating the need for test gas cylinders

Modular design for ease of service Self-monitoring function indicates when maintenance is required

— Application-oriented design Housing design for 19-inch rack mounting or wall mounting Optional integrated pneumatics module Ethernet, Modbus and PROFIBUS interfaces Configurable analog and digital inputs and outputs

— User-friendly operation Simultaneous digital and analog display of measured values on a large graphics panel

Menu-driven operator interface Clear-text status messages

AO2000 CONTINUOUS GAS ANALYZERS | DS/AO2000-EN REV. B 3

— Modular analyzer product line

Overview Advance Optima AO2000 Series is a line of modules used for con-tinuous process gas analysis.

The product line consists of the following modules:

Analyzer modules

Pneumatics module

Electronics module with system controller and I/O modules

Housing with display and control unit

System bus

The modules can be arranged in various ways to form single or multiple analyzer systems.

The electronics module, power supply and housing with display and control unit are also collectively referred to as the “central unit”.

Measuring technology (analyzer modules) Infrared photometer analyzer module Uras26

Process photometer analyzer modules Limas21 UV Limas21 HW

Oxygen analyzer modules Magnos206 Magnos28 Magnos27

Trace oxygen analyzer module ZO23

Thermal conductivity analyzer modules Caldos25 Caldos27

FID analyzer modules Fidas24 Fidas24 NMHC

Laser analyzer module LS25

Electrochemical oxygen sensor

Each analyzer module consists of the sensor and associated elec-tronics having its own processor.

The analyzer modules are linked to the system controller via the system bus. The laser analyzer module is linked to the central unit via Ethernet.

The analyzer modules are supplied with DC 24 V from an integral power supply or an external unit.

The electrochemical oxygen sensor is available as an option in combination with an analyzer module.

Pneumatics module The pneumatics module contains the following elements when fully equipped:

One or three solenoid valves to control test gas supply

One or two disposable filter elements for fine filtration

One gas supply pump with coarse filter and capillary

One or two flow monitors

The pneumatics module is always associated with an analyzer module and installed in the same housing as the analyzer module.

Electronics module, interfaces The electronics module incorporates the system controller with the I/O modules.

The system controller carries out the following functions:

Processing and communicating the measured values supplied by the analyzer module sensor electronics

Compensating measured values, e.g. cross sensitivity correction

Controlling system functions, e.g. calibration

Display and control functions

Controlling associated systems, e.g. gas supply

Communicating with external systems

The system controller communicates with the other functional units of the gas analyzer (e.g. the analyzer modules) via the system bus.

Interfaces for controlling associated systems and for communi-cating with external systems are located on the system controller (Ethernet 10/100/1000BASE-T interface) and on the I/O modules.

The I/O modules are attached and directly connected to the sys-tem controller board. There are six types of I/O modules:

Profibus modules have one RS485 and one MBP interface.

Modbus modules have one RS485 and one RS232 interface.

Digital I/O modules have four digital inputs and four digital outputs.

2-way analog output modules have two analog outputs.

4-way analog output modules have four analog outputs.

4-way analog input modules have four analog inputs.

Examples of I/O module applications include:

Output of measured values as current signals

Output of status and alarm signals

Calibration control

Control of external solenoid valves and pumps

Measurement range switching and feedback

Feed of current or status signals from external analyzers

Feed of status signals from peripherals


— … Modular analyzer product line

Housing The housing is available as a 19-inch rack-mount (model AO2020) or a wall-mount (model AO2040) unit with IP20 or IP54 protection.

IP54 housing versions can be purged.

The display and control unit is located on the front panel of the housing when the electronics module is installed.

System bus The gas analyzer’s functional units are interconnected via the system bus.

The system bus structure is linear with a maximum length of 350 meters.

Only one electronics module with up to five I/O modules should be connected to a system bus structure.

Connection of sample gas conditioning modules The SCC-F sample gas feed unit and the SCC-C sample gas cooler can be connected to the gas analyzer via the system bus by means of an I/O board installed in the sample gas feed unit.

Thus it is possible to display, monitor and control individual sam-ple gas conditioning functions in the gas analyzer such as cooler temperature or condensate and flow status.

For further information, please refer to the “System components and accessories for sample gas conditioning” data sheet.


— Configuration of analyzer units and multiple analyzer systems

This data sheet contains specifications for all modules and com-ponents in the Advance Optima AO2000 Series modular product line.

This data sheet was not intended to be used for configuring an analyzer unit or a multiple analyzer system. For a quotation please contact your ABB sales representative who can also pro-vide advice and support.

Example 1 shows the modules and components that normally make up an analyzer unit as well as the possibilities for configur-ing an analyzer unit.

The modular product line allows modules and components to be formed into an analyzer unit (see example 1) or into multiple ana-lyzer systems (see example 2).

Example 1: Analyzer unit configuration (19-inch housing)

Housing with display and control unit (see page 38) Housing type with / without display and control unit Power supply (unless otherwise specified on electronics module)

+

Electronics module (see page 41) Power supply I/O module equipment Interfaces

+

Analyzer modules (see pages 6 to 35) Gas path design Gas connections Type of installation Analyzer-specific data

=

System configuration Number of housings Number of analyzer modules System bus wiring DC 24 V analyzer power supply

Example 2: Multiple analyzer system variant (wall-mount housings)


— Infrared analyzer module Uras26

Measurement principle Non-dispersive infrared absorption in the λ = 2.5 to 8 μm wave-length range

Photometer to measure from 1 to 4 components with 1 or 2 beam paths and 1 or 2 receivers in each beam path

Sample components and measurement ranges The Uras26 analyzer module has one physical measurement range per sample component. As an option, smaller measurement ranges can be electronically derived from the physical measure-ment range. The smallest range is measurement range 1.

The smallest measurement ranges shown in the following table are based on the first sample component in beam path 1.

Sample compo-nent

Smallest class 1 range


Smallest class 2 range with cali-bration cell

Gas group 1)

CO 0– 50 ppm 0– 10 ppm 0– 50 ppm 2) A

CO2 0– 50 ppm 0– 5 ppm 0– 25 ppm 2) A

NO 0– 75 ppm 0– 75 ppm 0– 75 ppm 2) A

SO2 0– 100 ppm 0– 25 ppm 0– 25 ppm 2) A

N2O 0– 50 ppm 0– 20 ppm 0– 50 ppm 2) A

CH4 0– 100 ppm 0– 50 ppm 0– 50 ppm 2) A

NH3 0– 500 ppm 0– 30 ppm – B

C2H2 0– 200 ppm 0– 100 ppm 0– 100 ppm B

C2H4 0– 500 ppm 0– 300 ppm 0– 300 ppm B

C2H6 0– 100 ppm 0– 50 ppm 0– 50 ppm 2) B

C3H6 0– 250 ppm 0– 100 ppm 0– 100 ppm 2) B

C3H8 0– 100 ppm 0– 50 ppm 0– 50 ppm 2) B

C4H10 0– 100 ppm 0– 50 ppm 0– 50 ppm 2) B

C6H14 0– 500 ppm 0– 100 ppm 0– 100 ppm 2) B

R 134a 0– 100 ppm 0– 50 ppm 0– 50 ppm 2) B

SF6 0– 5 ppm 0– 4 ppm – B

H2O 0– 1000 ppm 0– 500 ppm 0– 500 ppm C

1) See price information 2) The smallest measurement range 1 is shown. The largest

measurement range should be at least four times larger.

Other sample components on request.

Measurement range quantity 1 to 4 ranges per sample component

Largest measurement range 0 to 100 vol.% or 0 vol.% to saturation or 0 vol.% to LEL Measurement ranges within ignition limits cannot be provided.

Measurement range ratio ≤ 1:20

Measurement ranges with suppressed zero-point Electronic zero-point suppression or differential measurement based on a base level > 0 with flowing reference gas, max. sup-pression ratio of 1:10

Stability The following data apply only if all influence factors (e.g. flow rate, temperature, atmospheric pressure) are constant. They ap-ply to measurement range 1 in a delivered analyzer module.

Linearity deviation ≤ 1 % of span Option: Linearization according to EPA specifications for auto-mobile exhaust gas measurement

Repeatability ≤ 0.5 % of span

Zero drift ≤ 1 % of span per week; for ranges smaller than class 1 to class 2: ≤ 3 % of span per week

Sensitivity drift ≤ 1 % of measured value per week

Output fluctuation (2 σ) ≤ 0.2 % of span at electronic T90 time = 5 sec (class 1) or = 15 sec (class 2)

Detection limit (4 σ) ≤ 0.4 % of span at electronic T90 time = 5 sec (class 1) or = 15 sec (class 2)

Influence effects Flow effect Flow rate in the 20 to 100 l/h range: Within detection limits

Associated gas effect / cross sensitivity The knowledge of the sample gas composition is necessary for the analyzer configuration. Selectivity measures to reduce associ-ated gas effect (optional): Incorporation of interference filters or filter vessels, internal electronic cross-sensitivity correction or carrier gas correction for a sample component by other sample components measured with the Uras26.

Temperature effect Ambient temperature in permissible range – At zero-point: ≤ 1 % of span per 10 °C;

for ranges smaller than class 1 to class 2: ≤ 2 % of span per 10 °C

– On sensitivity with temperature compensation: ≤ 3 % of measured value per 10 °C

– On sensitivity with thermostat effect at 55 °C (optional): ≤ 1 % of measured value per 10 °C

Air pressure effect – At zero-point: No effect – On sensitivity with pressure correction by means of integral

pressure sensor: ≤ 0.2 % of measured value per 1 % air pres-sure change

The pressure sensor is located in the sample gas path if hoses are used as the internal gas lines. If tubing is used for internal gas lines, the pressure sensor is routed to the outside via a hose.

Power supply effect DC 24 V ± 5 %: ≤ 0.2 % of span


Dynamic response Warm-up time Approx. 30 minutes without thermostat; approx. 2 hours with thermostat

90% response time T90 = 2.5 sec for measurement cell length = 200 mm and sample gas flow = 60 l/h without signal damping (low pass filter). Low-pass time constant adjustable from 0 to 60 sec.

Calibration Zero-point calibration With inert gas, e.g. nitrogen, or with ambient air that is free of the sample component.

End-point calibration With gas-filled calibration cells (optional) or with test gas mix-tures. It is recommended to verify the calibration cell set values once a year. During calibration of a multi-component analyzer, possible cross-sensitivity and / or carrier gas corrections by inter-nal or external measurement components are switched off. Therefore, corrected measurement components should be cali-brated only using a test gas consisting of the measurement com-ponent and an inert gas like nitrogen.

Materials in contact with the sample medium Analyzer (sample cells) Tubing: Aluminum or gold-plated aluminum. Window: CaF2, option: BaF2. Connectors: Stainless steel 1.4571 (SAE 316Ti).

Gas lines and connectors FPM hoses and PTFE tubing with stainless steel connectors. Option: Stainless steel tubes 1.4571 (SAE 316Ti).

Sample gas inlet conditions Temperature The sample gas dew point should be at least 5 °C below the am-bient temperature throughout the sample gas path. Otherwise, a sample gas cooler or condensate trap is required.

Pressure The analyzer module is operated under atmospheric pressure; the sample gas outlet is open to atmosphere. Internal pressure drop < 5 hPa with standard flow rate 60 l/h. Permissible absolute pres-sure range: 800 to 1250 hPa. Operation under lower absolute pres-sure (e.g. at altitudes above 2000 m) on request. Overpressure in the sample cell max. 500 hPa.

Flow rate 20 to 100 l/h

Corrosive gases Highly corrosive associated gas components, e.g. chlorine (Cl2) and hydrogen chloride (HCl), as well as gases or aerosols contain-ing chlorine must be cooled or undergo prior absorption. Provide for housing purge.

Flammable gases The analyzer module is suitable for measuring flammable gases and vapors under atmospheric conditions (pabs ≤ 1.1 bar, oxygen content ≤ 21 vol.%). Temperature class: T4. The sample gas must not be explosive under normal conditions.

If the sample gas is explosive in the event of a sample gas supply failure, then only seldom and briefly (in accordance with zone 2). Pressure in the sample gas path in normal operation pe ≤ 100 hPa; in case of a sample gas supply failure the pressure must not ex-ceed the maximum value pe = 500 hPa. The version with gas paths designed as stainless steel tubes should be selected and housing purge with nitrogen should be provided when measuring flammable gases and vapors. Before using the analyzer module, the corrosion resistance against the specific sample gas must be checked.

Version in category 3G see page 36

Gas connections The drawing below shows the gas connection arrangement in an exemplary manner for the three variants: A 1 gas path with 1 sample cell, B 1 gas path with 2 sample cells in series and C 2 separate gas paths with 1 sample cell each. The actual gas connection arrangement of an analyzer module is found in the analyzer data sheet for the delivered instrument.

1 Pressure sensor for external pressure measurement 1)

2 –3 Sample gas inlet A or B or C gas path 1 4 Sample gas outlet A or C gas path 1 5 Purge gas inlet housing 1)

6 Purge gas outlet housing 1) (also with flow sensor)7 Sample gas inlet C gas path 2 1) 8 Sample gas outlet B or C gas path 2 1) 9 Reference gas inlet gas path 1 1)

10 Reference gas outlet gas path 1 1) Pneumatics module 1):

11 Sample gas inlet A or B or C gas path 1 12 End point gas inlet (with 3 solenoids) or

sample gas inlet C gas path 2 (only with flow sensor)13 Test gas / zero-point gas inlet (with 1 or 3 solenoids) or

sample gas outlet C gas path 2 (only with flow sensor) – in this case connect with sample gas inlet 7

14 Sample gas outlet A or B or C gas path 1 – connect with sam-ple gas inlet 3

1) Option

1

2

3

4567

8

9

10

11

1213

14


— Process photometer analyzer module Limas21 UV

Measurement principle and application Gas filter correlation or wavelength comparison in ultraviolet and visible spectrum range λ = 200 to 600 nm

Photometer to measure from 1 to 4 components

Sample cells made from various materials are available for meas-uring in corrosive, toxic and flammable gases (see page 12)

Sample components and measurement ranges The Limas21 UV analyzer module has one physical measurement range per sample component. As an option, smaller measure-ment ranges can be electronically derived from the physical measurement range. The smallest range is measurement range 1.

Sample component



Gas group 1)

NO 2) 0– 50 ppm 0– 10 ppm A

SO2 0– 150 ppm 0– 25 ppm A

NO2 0– 250 ppm 0– 50 ppm B

NH3 0– 100 ppm 0– 30 ppm B

H2S 0– 50 ppm 0– 25 ppm B

Cl2 0– 250 ppm 0– 100 ppm D

CS2 0– 100 ppm 0– 50 ppm C

COS 0– 500 ppm 0– 250 ppm C

1) See price information 2) The UV-RAS (ultra-violet resonant absorption spectroscopy)

method is used to make the analyzer selective to the sample component NO.


Measurement range quantity 1 to 4 ranges per sample component

Largest measurement range 0 to 100 vol.% or 0 vol.% to saturation or 0 vol.% to LEL Measurement ranges within ignition limits cannot be provided.

Measurement range ratio Measurement ranges freely adjustable within a range ratio of 1:20 relative to the factory-set reference measurement range.

Measurement ranges with suppressed zero-point Electronic zero-point suppression, max. suppression ratio of 1:10

Stability The following data apply only if all influence factors (e.g. flow rate, temperature, atmospheric pressure) are constant. They ap-ply to measurement range 1 in a delivered analyzer module.

Linearity deviation ≤ 1 % of span Option: Linearization acc. to EPA specifications for automotive exhaust gas measurement


Zero drift ≤ 2 % of span per week; for ranges smaller than class 1 to class 2: ≤ 1.5 % of span per day (recommendation: daily automatic zero-point calibration)


Output fluctuation (2 σ) ≤ 0.5 % of span at electronic T90 time = 10 sec; for ranges smaller than class 1 to class 2: ≤ 1 % of span

Detection limit (4 σ) ≤ 1 % of span; for ranges smaller than class 1 to class 2: ≤ 2 % of span

Influence effects Flow effect Flow rate in the 20 to 100 l/h range: Within detection limits

Associated gas effect/cross sensitivity The knowledge of the sample gas composition is necessary for the analyzer configuration. Selectivity measures to reduce associ-ated gas effect (optional): Incorporation of filters cells or internal electronic cross-sensitivity correction or carrier gas correction for a sample component by other sample components measured with the Limas21 UV.

Temperature effect Ambient temperature in permissible range, Sample cell thermostat control to +60 °C – At zero-point: ≤ 1 % of span per 10 °C; for ranges smaller than

class 1 to class 2: ≤ 2 % of span per 10 °C – On sensitivity: ≤ 1 % of measured value per 10 °C



The pressure sensor is located in the sample gas path if hoses are used as the internal gas lines. If tubing is used for internal gas lines, the pressure sensor is routed to the outside via a hose.



Dynamic response Warm-up time Approx. 2.5 hours

90% response time T90 = 4 sec for measurement cell length = 262 mm and sample gas flow = 60 l/h without signal damping (low pass filter). Low-pass time constant adjustable from 0 to 60 sec

Calibration Zero-point calibration With inert gas, e.g. nitrogen, or with ambient air that is free of the sample component

End-point calibration With gas-filled calibration cells (optional) or with test gas. It is recommended to verify the calibration cell set values once a year. During calibration of a multi-component analyzer, possible cross-sensitivity and/or carrier gas corrections by internal or external measurement components are switched off. Therefore, corrected measurement components should be calibrated only using a test gas consisting of the measurement component and an inert gas like nitrogen.

Materials in contact with the sample medium See page 12

Sample gas inlet conditions Temperature The sample gas dew point should be at least 5 °C below the am-bient temperature throughout the sample gas path. Otherwise, a sample gas cooler or condensate trap is required.



Corrosive, toxic and flammable gases See page 12

Purge gas See page 12

Gas connections See page 13


— Process photometer analyzer module Limas21 HW

Measurement principle and application Limas21 HW is a multi-component analyzer for simultaneous measurement of nitrogen compounds in wet sulfur-free flue gas without converter.

Measurement principle

Photometer to measure NO, NO2 and NH3.

The UV-RAS method (ultra-violet resonant absorption spectros-copy) is used to make the analyzer selective to the sample com-ponent NO.

Wavelength comparison in ultraviolet spectrum range λ = 200 to 600 nm.

Applications

Exhaust gas measurement for the development of combustion engines and methods for exhaust gas after-treatment, in particu-lar for pure gas measurement after catalyst in – Four-stroke gasoline and diesel engines, – Catalysts for nitrogen oxide reduction.

Process measurement e.g. for monitoring, controlling and opti-mizing DeNOx SCR processes.

Sample components and measurement ranges (recommendations), stability data Exhaust gas measurement for four-stroke gasoline and diesel engines

Sample component Smallest range Largest range

NO 0–100 ppm 0–5000 ppm

NO2 0–100 ppm 0–2500 ppm

Linearity deviation ≤ 1 % of span, ≤ 2 % of measured value acc. to EPA specifications for automotive exhaust gas measurement


Zero drift ≤ 1 ppm or ≤ 1 % of span per 24 hours based on the smallest rec-ommended measurement range (daily automatic zero-point cali-bration recommended)


Output fluctuation (2 σ) ≤ 400 ppb or ≤ 0.4 % of span at electronic T90 time = 5 sec

Detection limit (4 σ) ≤ 800 ppb or ≤ 0.8 % of span at electronic T90 time = 5 sec

Diluted exhaust gas measurement for four-stroke gasoline and diesel engines, bag measurement


NO 0–10 ppm 0–500 ppm

NO2 0–10 ppm 0–500 ppm

Linearity deviation ≤ 1 % of span, ≤ 2 % of measured value acc. to EPA specifications for automotive exhaust gas measurement


Zero drift ≤ 250 ppb or ≤ 2 % of span per 8 hours based on the smallest rec-ommended measurement range (daily automatic zero-point cali-bration recommended)


Output fluctuation (2 σ) NO ≤ 50 ppb or ≤ 0.5 % of span, NO2 ≤ 60 ppb or ≤ 0.5 % of span at electronic T90 time = 15 sec

Detection limit (4 σ) NO ≤ 100 ppb or ≤ 1 % of span, NO2 ≤ 120 ppb or ≤ 1 % of span at electronic T90 time = 15 sec

Process measurement


NO 0–100 ppm 0–1000 ppm

NO2 0–100 ppm 0– 500 ppm

NH3 0–100 ppm 0– 500 ppm

Linearity deviation ≤ 1 % of span


Zero drift ≤ 1 ppm or ≤ 1 % of span per 24 hours based on the smallest rec-ommended measurement range (daily automatic zero-point cali-bration recommended)


Output fluctuation (2 σ) ≤ 150 ppb or ≤ 0.15 % of span at electronic T90 time = 30 sec

Detection limit (4 σ) ≤ 300 ppb or ≤ 0.3 % of span at electronic T90 time = 30 sec

Measurement ranges Quantity 1 to 4 ranges per sample component

Measurement range ratio Max. 1:20. Measurement ranges are freely adjustable within a range ratio of 1:20 relative to the factory-set reference measure-ment range. Max. 1:50 for fixed measurement ranges acc. to EPA specifications for automotive exhaust gas measurement.


Influence effects Flow effect Flow rate in the 20 to 90 l/h range: within detection limits

Associated gas effect/cross sensitivity The knowledge of the sample gas composition is necessary for the analyzer configuration. Selectivity measures to reduce associ-ated gas effect: Internal electronic cross-sensitivity correction or carrier gas correction for a sample component by other sample components measured with the Limas21 HW.

Temperature effect Ambient temperature in permissible range, Sample cell thermostat control to +82 °C – At zero-point: ≤ 2 % of span per 10 °C – On sensitivity: ≤ 2 % of measured value per 10 °C



The pressure sensor is routed to the outside via a hose.


Dynamic response Warm-up time Approx. 4 hours

90% response time T90 ≤ 5 sec for measurement cell length = 260 mm and sample gas flow = 60 l/h with non-linear filter (static/dynamic) = 15/1 sec. Low-pass time constant adjustable from 0 to 30 sec.

Calibration Zero-point calibration With inert gas, e.g. nitrogen, or with ambient air that is free of the sample component

End-point calibration With gas-filled calibration cells (optional) or with test gas. It is recommended to verify the calibration cell set values once a year. During calibration of a multi-component analyzer, possible cross-sensitivity and/or carrier gas corrections by internal or external measurement components are switched off. Therefore, corrected measurement components should be calibrated only using a test gas consisting of the measurement component and an inert gas like nitrogen.

Materials in contact with the sample medium Sample cell Tubing and window: Silica glass, Screw connection: PVDF, Connectors: PTFE

Gas lines and connectors Stainless steel 1.4305 (SAE 303), 1.4571 (SAE 316Ti)

Housing purge Purge gas Sample component-free air or nitrogen Purge gas flow rate ≤ 10 l/h

Sample gas inlet conditions Sample gas composition Sulfur-free exhaust gas of combustors, SO2 concentration < 25 ppm, H2O < 20 vol.%, filtered with pore width ≤ 0.5 µm

Temperature Sample gas dew point ≤ 60 °C



Gas connections See page 13

Notes The analyzer module Limas21 HW can only be mounted in the 19-inch housing.

SO2 influences the NH3 reading. If the sample gas mixture con-tains SO2, the requirement of internal corrections must be scruti-nized.

When ordering the average water vapor concentration has to be specified. The influence is corrected internally.

Sample conditioning system requirements Sample gas feed-in The various applications require the sample gas feed-in to the gas analyzer at temperatures of 150 to 190 °C. It is imperative to eliminate condensation and sublimation since NH3 and NO2 are easy soluble in water and can result in salification. It is also im-perative to prevent condensation of potentially present low-boil-ing hydrocarbons.

Sample gas inlet temperature (on the process side) 150 to 190 °C

Sample gas filter For NO and NO2 measurement: Sintered metal; for NH3 measure-ment: Ceramics; pore width ≤ 0.5 μm

Materials in contact with the sample medium PTFE, PVDF or Silicosteel

Exhaust gas conditions Outlet pressure = atmospheric pressure, no resistance in the gas outlet.

Installation note Route the exhaust gas line declining to allow for condensate drain-off.


— Process photometer analyzer modules Limas21 UV, Limas21 HW

Sample cells

Standard cell Quartz cell Safety cell

Application Standard applications Corrosive gases Corrosive, toxic and flammable gases

Wavelength range 200 to 10000 nm 200 to 4000 nm CaF2 window: 200 to 10000 nmSiO2 window: 200 to 4000 nm

Resistance 1)

Suitable for measurement of … Non-corrosive gases Corrosive gases, e.g. wet Cl2, wet HCl, H2SO4, SO3, ozone

Corrosive gases, e.g. dry HCl, dry COCl2 (< 50 ppm H2O)

Not suitable for measurement of … Highly corrosive gases, e.g. gases containing chlorine, H2SO4, SO3, fluorine com-pounds

Fluorine compounds Wet gases containing chlorine, H2SO4, SO3, fluorine com-pounds

Safety principle

Toxic gases Housing purge (≤ 20 l/h) with sample component-free air or with N2

Housing purge (≤ 20 l/h) with sample component-free air or with N2

Cell purge 2) with N2 or with sample component-free air with negative pressure and flow monitoring; additional monitoring for sample gas traces possible

Corrosive gases PTFE gas lines, housing purge (≤ 20 l/h) with sample compo-nent-free air or with N2

Housing purge (≤ 20 l/h) with sample component-free air or with N2

Cell purge 2) with N2 or with sample component-free air with excess pressure 3) and flow monitoring

Flammable gases 4) Stainless steel gas lines, housing purge (≤ 20 l/h) with N2

Housing purge (≤ 20 l/h) with N2

Cell purge 2) with N2

Seal integrity < 1 x 10−3 hPa l/s < 1 x 10−6 hPa l/s < 1 x 10−6 hPa l/s

Pressure rating

Continuous pe < 500 hPa pe < 500 hPa pe < 500 hPa

Spike – pabs < 300 kPa pabs < 500 kPa

Sample cell material

Cell tube Aluminum Silica glass (SiO2) Stainless steel 1.4571 (SAE 316Ti)

Window CaF2, adhesive fastening Silica glass CaF2 or SiO2, threaded fastening

Seal – FFKM75 FFKM70

Connectors SS 1.4571 (SAE 316Ti) PFA SS 1.4571 (SAE 316Ti)

Gas line materials FPM or PTFE PFA SS 1.4571 (SAE 316Ti)

Gas connector materials SS 1.4571 (SAE 316Ti) PFA SS 1.4571 (SAE 316Ti)

Sample gas connection design (connection drawings see page 13)

Connectors with ⅛ NPT inter-nal threads

Pipes 6/4 mm Pipes with 4 mm outer diame-ter

1) see pages 9, 11, Fehler! Textmarke nicht definiert. “Sample gas inlet conditions”

4) The analyzer module is suitable for measuring flammable gases and vapors under atmos-pheric conditions (pabs ≤ 1.1 bar, oxygen content ≤ 21 vol.%). Temperature class: T4. The sam-ple gas must not be explosive under normal conditions. If the sample gas is explosive in the event of a sample gas supply failure, then only seldom and briefly (in accordance with zone 2). Pressure in the sample gas path in normal operation pe ≤ 100 hPa; in case of a sample gas supply failure the pressure must not exceed the maximum value pe = 500 hPa. Before using the analyzer module, the corrosion resistance against the specific sample gas must be checked.

2) purge curtain

3) pe = 7 to 20 hPa, 15 to 20 l/h


Gas connections Limas21 UV: Standard cell with FPM or PTFE hoses, quartz cell with FPM or PTFE hoses, center connection cell made of alumi-num or quartz

Limas21 UV: Quartz cell with PFA tubes

1 Sample gas inlet 1 Sample gas inlet3 Purge gas inlet housing 1) 3 Purge gas inlet housing 1)

4 Sample gas outlet 4 Sample gas outlet6 Purge gas outlet housing 1) 6 Purge gas outlet housing 1)

7 Pressure sensor 2) 7 Pressure sensor8 End-point gas inlet (with 3 solenoids) 1) 3) 1) Option 9 Zero-point gas inlet (with 1 or 3 solenoids) 1) 3) 1) Option 2) external connection, not for standard cell with FPM hoses3) not for version with PTFE hoses

Limas21 UV: Safety cell Limas21 HW

1 Sample gas inlet 1 Sample gas inlet2 Sample gas outlet 3 Purge gas inlet housing3 Purge gas inlet housing 1) 4 Sample gas outlet4 Purge gas inlet sample cell 6 Purge gas outlet housing5 Purge gas outlet sample cell 7 Pressure sensor6 Purge gas outlet housing 1) 7 Pressure sensor

1) Option

7

8

9

1

3

4

6

BUS

Service

24 V DC

7

1

3

4

6

BUS

Service

24 V DC

7

1

2

3

4

5

6

BUS

Service

24 V DC

BUS

Service

24 V DC

7

6 3

1

4


— Oxygen analyzer module Magnos206

Measurement principle Paramagnetic behavior of oxygen

Magnetomechanical oxygen analyzer

Sample component and measurement ranges Sample component Oxygen (O2)

Smallest measurement range 0 to 0.5 vol.% O2

Measurement range quantity and limits 4 measurement ranges Measurement ranges are freely adjustable; they are factory-set to 0 to 10/15/25/100 vol.% O2 or per order.

Largest measurement range 0 to 100 vol.% O2 Measurement ranges within ignition limits cannot be provided.

Measurement ranges with suppressed zero-point Max. measurement range suppression 1:100, e.g. 99 to 100 vol.% O2. Highly suppressed measurement ranges (≥95 to 100 vol.% O2) and initial measurement ranges in the same analyzer should be avoided. Pressure correction by means of pressure sensor required.

Stability Linearity deviation ≤ 0.5 % of span, minimum 0.005 vol.% O2

Repeatability ≤ 50 ppm O2 (time base for gas exchange ≥ 5 minutes)

Zero drift ≤ 3 % of span of the smallest measurement range (per order) per week, minimum 300 ppm O2 per week; following prolonged transport and storage time the drift can be higher during the first weeks of operation.

Sensitivity drift ≤ 0.1 vol.% O2 per week or ≤ 1 % of measured value per week (not cumulative), whichever is smaller. ≤ 0.25 % of measured value per year, minimum 0.05 vol.% O2 per year

Output fluctuation (2 σ) ≤ 25 ppm O2 at electronic T90 time (static/dynamic) = 3/0 sec

Detection limit (4 σ) ≤ 50 ppm O2 at electronic T90 time (static/dynamic) = 3/0 sec

Influence effects Flow effect ≤ 0.1 vol.% O2 in permissible range

Associated gas effect Data regarding the effect of associated gases can be found in IEC 61207-3:2002 “Gas analyzers – Expression of performance – Part 3: Paramagnetic oxygen analyzers”.

Temperature effect Ambient temperature in permissible range – At zero-point: ≤ 0.02 vol.% O2 per 10 °C – On sensitivity: ≤ 0.3 % of measured value per 10 °C Thermostat temperature = 64 °C

Air pressure effect – On sensitivity without pressure correction:

≤ 1 % of measured value per 1 % air pressure change – On sensitivity with pressure correction using integrated pres-

sure sensor (optional): ≤ 0.1 % of measured value per 1 % air pressure change; for highly suppressed measurement ranges ≤ 0.01 % of measured value per 1 % air pressure change or ≤ 0.002 vol.% O2 per 1 % air pressure change, whichever is greater.


Position effect Zero-point shift ≤ 0.05 vol.% O2 per 1° deviation from horizontal location. Position has no effect on the hard-mounted unit.

Dynamic response Warm-up time < 1 hour

90% response time T90 ≤ 3.5 to 10 sec at a sample gas flow of 90 l/h and electronic T90 time (static/dynamic) = 3/0 sec, gas change from nitrogen to air (applies to an analyzer unit with 1 analyzer module)

Calibration Zero-point calibration With oxygen-free process gas or substitute gas

End-point calibration With process gas with a known oxygen concentration or a substi-tute gas such as dried air

Single-point calibration For measurement ranges from 0–5 to 0–25 vol.% O2: Zero-point calibration with any oxygen concentration, e.g. with nitrogen or ambient air, processed through a cooler or H2O ab-sorber. Pressure correction by means of pressure sensor is recom-mended for single-point calibration with air. Depending on the measurement task involved, the zero- and end-points should be verified periodically (recommendation: once a year).

Calibration of measurement ranges with suppressed zero-point Highly suppressed measurement ranges (≥95 to 100 vol.% O2) should only be calibrated with test gases with concentrations in the selected measurement range. Single-point calibration can also be done within a suppressed measurement range. The O2 concentration of the test gas must lie within the measurement range.


Materials in contact with the sample medium Analyzer Stainless steel 1.4305 (SAE 303), glass, platinum, rhodium, epoxy resin; FPM seals, optional: FFKM75

Sample gas inlet conditions Temperature +5 to +50 °C The sample gas dew point should be at least 5 °C below the am-bient temperature throughout the sample gas path. Otherwise, a sample gas cooler or condensate trap is required. Water vapor content variations cause volume errors.

Pressure Operation under atmospheric pressure: The sample gas outlet is open to atmosphere. Internal pressure drop < 5 hPa with standard flow rate 60 l/h. Permissible absolute pressure range: 800 to 1250 hPa. Operation under lower absolute pressure (e.g. at alti-tudes above 2000 m) on request. Operation under elevated pressure: A pressure sensor is required for pressure influence compensation. Absolute pressure ≤ 1250 hPa: An optional internal pressure sen-sor can be connected to the sample gas path. Absolute pressure ≥ 1250 hPa: An external pressure sensor must be connected to the sample gas path. The analyzer module is function-tested for 5000 hPa internal pres-sure without damage.

Flow rate 30 to 90 l/h Changes in gas flow rates should be avoided when using highly suppressed measurement ranges.

Corrosive gases Consultation with ABB Analytical is required if the sample gas contains Cl2, HCl, HF or other corrosive components. FFKM75 seals must be used if the sample gas contains NH3. In this case, the pneumatics module cannot be connected to the analyzer module. The pressure sensor must not be connected to the sam-ple gas path.

Flammable gases The analyzer module is suitable for measuring flammable gases and vapors under atmospheric conditions (pabs ≤ 1.1 bar, oxygen content ≤ 21 vol.%). Temperature class: T4. The sample gas must not be explosive under normal conditions. If the sample gas is explosive in the event of a sample gas supply failure, then only seldom and briefly (in accordance with zone 2). Pressure in the sample gas path in normal operation pe ≤ 100 hPa; in case of a sample gas supply failure the pressure must not ex-ceed the maximum value pe = 500 hPa. Before using the analyzer module, the corrosion resistance against the specific sample gas must be checked. Housing purge with nitrogen should be provided when measur-ing flammable gases and vapors. Flame barriers can be used as an option (except for the “safety concept” version, see page 36). Pressure drop at the flame barriers approx. 40 hPa for a sample gas flow rate of 50 l/h. Material of the flame barriers: Stainless steel 1.4571 (SAE 316Ti). The pressure sensor must not be con-nected to the sample gas path.


Gas connections The sample cell is connected directly to the gas ports.

1 Sample gas inlet2 Sample gas outlet3 Purge gas inlet analyzer 2)

4 Purge gas outlet analyzer 2) 7 Purge gas inlet housing 1)

8 Purge gas outlet housing 1) (also with flow sensor)9 Pressure sensor 1 1)

10 Pressure sensor 2 1)

Pneumatics module 1):11 Sample gas inlet12 End point gas inlet (with 3 solenoids) 13 Test gas / zero-point gas inlet (with 1 or 3 solenoids)14 Sample gas outlet – connect with sample gas inlet 11) Option2) not in version with performance test for emission monitoring

1 2

3 4

13 14

12 11 10 9 8 7




Magnetomechanical oxygen analyzer


Smallest measurement range 0 to 0.5 vol.% O2

Measurement range quantity and limits 4 measurement ranges Measurement ranges are freely adjustable; they are factory-set to 0 to 10/15/25/100 vol.% O2 or per order.


Measurement ranges with suppressed zero-point Max. measurement range suppression 1:100, e.g. 99 to 100 vol.% O2. The combination of a suppressed and an initial measurement range is not possible. Pressure correction by means of pressure sensor required. The pressure sensor is equipped by the manufacturer when the analyzer has been or-dered with a suppressed measurement range.

Stability The following data apply only if all influence factors (e.g. flow rate, temperature, atmospheric pressure) are constant.

Linearity deviation ≤ 0.5 % of span, minimum 0.005 vol.% O2

Repeatability ≤ 50 ppm O2

Zero drift ≤ 3 % of span of the smallest measurement range (per order) per week, minimum 300 ppm O2 per week

Sensitivity drift ≤ 0.1 vol.% O2 per week or ≤ 1 % of measured value per week (not cumulative), whichever is smaller; ≤ 0.15 % of measured value per three months, minimum 0.03 vol.% O2 per three months

Output fluctuation (2 σ) ≤ 25 ppm O2 at electronic T90 time (static/dynamic) = 3/0 sec

Detection limit (4 σ) ≤ 50 ppm O2 at electronic T90 time (static/dynamic) = 3/0 sec

Influence effects Flow effect ≤ 0.1 vol.% O2 in permissible range

Associated gas effect Data regarding the effect of associated gases can be found in IEC 61207-3:2002 “Gas analyzers – Expression of performance – Part 3: Paramagnetic oxygen analyzers”.

Temperature effect Ambient temperature in permissible range – At zero-point: ≤ 0.02 vol.% O2 per 10 °C – On sensitivity: ≤ 0.3 vol.% O2 per 10 °C Thermostat temperature = 60 °C

Air pressure effect – On sensitivity without pressure correction:

≤ 1 % of measured value per 1 % air pressure change – On sensitivity with pressure correction using integrated pres-

sure sensor (optional): ≤ 0.1 % of measured value per 1 % air pressure change; for highly suppressed measurement ranges ≤ 0.01 % of measured value per 1 % air pressure change or ≤ 0.002 vol.% O2 per 1 % air pressure change, whichever is greater

Power supply effect DC 24 V ± 5 %: within detection limit

Position effect Zero-point shift ≤ 0.05 vol.% O2 per 1° deviation from horizontal location. Position has no effect on the hard-mounted unit.

Dynamic response Warm-up time < 1 hour

90% response time T90 ≤ 3.0 sec at a sample gas flow of 90 l/h and electronic T90 time (static/dynamic) = 3/0 sec, gas change from nitrogen to air (applies to an analyzer unit with 1 analyzer module)


End-point calibration With process gas with a known oxygen concentration or a substi-tute gas such as dried air

Single-point calibration For measurement ranges from 0–5 to 0–25 vol.% O2: Zero-point calibration with any oxygen concentration, e.g. with nitrogen or ambient air, processed through a cooler or H2O ab-sorber. Pressure correction by means of pressure sensor is recom-mended for single-point calibration with air. Depending on the measurement task involved, the zero- and end-points should be verified periodically (recommendation: once a year).

Calibration of measurement ranges with suppressed zero-point Highly suppressed measurement ranges (≥95 to 100 vol.% O2) should only be calibrated with test gases with concentrations in the selected measurement range. Single-point calibration can also be done within a suppressed measurement range. The O2 concentration of the test gas must lie within the measurement range.


Materials in contact with the sample medium Analyzer Stainless steel 1.4305 (SAE 303), nickel alloy, glass, PtNi, silicon, gold, PTFE; FPM seals, optional: FFKM75

Sample gas inlet conditions The analyzer module must not be used for measurement of ignit-able gas/air or gas/oxygen mixtures.

Temperature +5 to +50 °C The sample gas dew point should be at least 5 °C below the am-bient temperature throughout the sample gas path. Otherwise, a sample gas cooler or condensate trap is required. Water vapor content variations cause volume errors.

Pressure Operation under atmospheric pressure: The sample gas outlet is open to atmosphere. Internal pressure drop < 5 hPa with standard flow rate 60 l/h. Permissible absolute pressure range: 800 to 1250 hPa. Operation under lower absolute pressure (e.g. at alti-tudes above 2000 m) on request. Operation under elevated pressure: A pressure sensor is required for pressure influence compensation. Absolute pressure ≤ 1250 hPa: An optional internal pressure sen-sor can be connected to the sample gas path. Absolute pressure ≥ 1250 hPa: An external pressure sensor must be connected to the sample gas path.

Flow rate 30 to 90 l/h Changes in gas flow rates should be avoided when using highly suppressed measurement ranges.

Corrosive gases Consultation with ABB Analytical is required if the sample gas contains Cl2, HCl, HF or other corrosive components. FFKM75 seals must be used if the sample gas contains NH3. In this case, the pneumatics module cannot be connected to the analyzer module. The pressure sensor must not be connected to the sam-ple gas path.

Flammable gases The analyzer module is suitable for measuring flammable gases and vapors under atmospheric conditions (pabs ≤ 1.1 bar, oxygen content ≤ 21 vol.%). Temperature class: T4. The sample gas must not be explosive under normal conditions. If the sample gas is explosive in the event of a sample gas supply failure, then only seldom and briefly (in accordance with zone 2). Pressure in the sample gas path in normal operation pe ≤ 100 hPa; in case of a sample gas supply failure the pressure must not ex-ceed the maximum value pe = 500 hPa. Before using the analyzer module, the corrosion resistance against the specific sample gas must be checked. Housing purge with nitrogen should be provided when measur-ing flammable gases and vapors. Flame barriers can be used as an option. Pressure drop at the flame barriers approx. 40 hPa for a sample gas flow rate of 50 l/h. Material of the flame barriers: Stainless steel 1.4571 (SAE 316Ti). The pressure sensor must not be connected to the sample gas path.

Gas connections 19-inch housing (model AO2020)

The sample cell is connected directly to the gas ports.

Wall-mount housing (model AO2040)


1 Sample gas inlet2 Sample gas outlet3 Purge gas inlet analyzer 2)

4 Purge gas outlet analyzer 2) 7 Purge gas inlet housing 1)



Pneumatics module 1):11 Sample gas inlet12 End point gas inlet (with 3 solenoids) 13 Test gas / zero-point gas inlet (with 1 or 3 solenoids)14 Sample gas outlet – connect with sample gas inlet 11) Option2) not in version with performance test for emission monitoring

2

1

3

4

13 14

12 11 10 9 8 7

1

2

3

4

13 14

12 11 10 9 8 7




Heavy-duty thermomagnetic analyzer

Sample component and measurement ranges Sample component Oxygen (O2) in flue gas or in nitrogen

Smallest measurement range 0 to 3 vol.% O2

Measurement range quantity 1 to 4 measurement ranges Ranges are factory-set per customer order.


Stability Linearity deviation ≤ 2 % of span

Repeatability ≤ 1 % of span

Zero drift ≤ 1 % of span per week


Output fluctuation (2 σ) ≤ 0.5 % of smallest measurement range span at electronic T90 time = 0 sec

Detection limit (4 σ) ≤ 1 % of smallest measurement range span at electronic T90 time = 0 sec

Influence effects Flow effect ≤ 1 % of span at a flow change of ±10 l/h. At an identical flow rate for test and sample gases, the flow rate effect is automatically compensated.

Associated gas effect The calibration applies only to the sample gas (= sample compo-nent + associated gas) shown on the identification plate.

Temperature effect Ambient temperature in permissible range – At zero-point: ≤ 2 % of span per 10 °C – On sensitivity: ≤ 0.5 % of measured value per 10 °C relative to temperature at the time of calibration Thermostat temperature = 63 °C

Air pressure effect – At zero-point: < 0.05 vol.% O2 per 1 % air pressure change – On sensitivity without pressure correction:

≤ 1.5 % of measured value per 1 % air pressure change – On sensitivity with pressure correction:

≤ 0.25 % of measured value per 1 % air pressure change Option: Calibration for operating altitude over 2000 m


Position effect Approx. 3 % of smallest measurement range span per 1° deviation from horizontal orientation. Position has no effect on the hard-mounted unit.

Dynamic response Warm-up time 2 to 4 hours

90% response time T90 = 10 to 22 sec, depending on sample gas flow and on meas-urement cell connection (see “Gas connections”, applies to an an-alyzer unit with 1 analyzer module)


End-point calibration With process gas having a known oxygen concentration or with substitute gas


Materials in contact with the sample medium Analyzer Stainless steel 1.4580 (SAE 316Cb) and 1.4305 (SAE 303), glass

Gas lines and connectors Stainless steel 1.4571 (SAE 316Ti) and 1.4305 (SAE 303), PVC-C, FPM




Flammable gases Measurement of flammable gases is not possible.

Gas connections Sample cell connection by means of FPM hoses

Sample cell direct connection

The sample cell is connected directly to the gas ports (for wall-mount housing only). Application e.g. when external gas supply is connected and for short T90 times.

1 Purge gas inlet housing 1)

2 Purge gas outlet housing 1) (also with flow sensor)3 –4 Sample gas inlet5 Purge gas inlet analyzer6 Purge gas outlet analyzer7 Sample gas outlet8 –9 Pressure sensor 1 1)


Pneumatics module 2):11 Sample gas inlet12 End point gas inlet (with 3 solenoids) 13 Test gas / zero-point gas inlet (with 1 or 3 solenoids)14 Sample gas outlet – connect with sample gas inlet 41) Option2) Option – not in version with sample cell direct connection

1

2

3

4567

8

9

10

11

12

14

13

1

2 10

9

4

7

68

5


— Trace oxygen analyzer module ZO23

Measurement principle Potentiometric measurement; zirconium dioxide cell for determi-nation of the oxygen concentration in accordance with Nernst’s equation; reference gas: ambient air.

The analyzer module is used for the continuous measurement of oxygen in pure gases (N2, CO2, and Ar). The measuring cell is cata-lytically inactivated to the extent that flammable carrier compo-nents in stoichiometric concentrations only negligibly reduce the oxygen value.


Measurement range quantity and limits 4 measurement ranges Measurement ranges are freely adjustable within the 0 to 1 ppm to 0 to 250,000 ppm O2 range; they are factory-set to 0 to 1/10/100/1000 ppm O2 The following measurement data refer to a measurement span of 100 ppm O2 with a regulated flow rate of 8 ± 0.2 l/h.

Stability Linearity Owing to the measurement principle, zirconium dioxide cells are base linear.

Repeatability < 1 % of the measurement range or 100 ppb O2 (whichever is greater)

Zero drift The zero point (reference point) is displayed if ambient air is pre-sent on the sample gas side. The value for air of 20.6 vol.% O2 (for 25 °C and 50 % relative humidity) may deviate through aging of the cell. < 1 % of the measurement range per week or 250 ppb O2 (which-ever is greater)

Sensitivity drift Depends on possible interfering components (catalyst poisons) in the sample gas and the aging of the cell. For pure gas measurements in N2, CO2 and Ar: < 1 % of the meas-urement range per week or 250 ppb O2 (whichever is greater)

Output fluctuation (2 σ) < ±0.5 % of the measured value or 50 ppb O2 (whichever is greater)

Detection limit (4 σ) < ±1 % of the measured value or 100 ppb O2 (whichever is greater)

Influence effects Flow effect ≤ 300 ppbv O2 in the permissible range

Associated gas effect Inert gases (Ar, CO2, and N2) have no effect. Flammable gases (CO, H2, CH4) in stoichiometric concentrations to the oxygen con-tent: Conversion of O2 < 20 % of the stoichiometric conversion. If higher concentrations of flammable gases are present, higher O2 conversions must be expected. The concentration of flammable gases in the sample gas must not exceed 100 ppm.

Temperature effect The effect of the ambient temperature in the permissible range of +5 to +45 °C is < 2 % of the measured value or 50 ppb O2 per 10 °C change in the ambient temperature (whichever is greater).

Air pressure effect No effect through a change in air pressure; sample gas must flow out of the outlet without backpressure.

Power supply effect DC 24 V ± 5 %: no effect

Position effect No position effect for permanently installed instruments

Dynamic response Warm-up time The operating temperature of the cell is reached after approx. 15 min. Offset calibration with reference gas (ambient air) after 2 h flow. The measurement is ready-to-run after valves and lines have been purged with sample gas. Typical purging time for valves and lines: approx. 2 to 5 h.

90% response time T90 < 60 s for the alternation of 2 test gases in the measurement range 10 ppm with a sample gas flow rate = 8 l/h and electronic T90 time = 3 s

Calibration Offset calibration The reference value for ambient air is calibrated at 20.6 vol.% O2 by means of ambient air on the sample gas side.

End-point calibration By means of test gas O2 in N2 (or in CO2 or Ar); O2 concentration in the measurement range, e.g. 10 ppm O2

Function test Extended response time or reduced sensitivity are dimensions for the correct functioning of the measuring cell. The function test can be carried out without any additional test gases by feed-ing the sample gas with constant concentration. Based on the progression of the test, it can be assessed whether the reaction time of the sensor lies within a specified tolerance. The function test is started manually and lasts approx. 15 min. An additional function block configuration is required for a cyclic scan.


Materials in contact with the sample medium Analyzer Zirconium dioxide cell: ZrO2, electrodes containing platinum; Dust filter (option): PP; Flow sensor (option): on semiconductor basis, nickel-plated brass

Gas lines and connectors Stainless steel 1.4571 (SAE 316Ti), FPM and silicon hoses in the gas outlet; Gas connections: stainless steel 1.4401/1.4305 (SAE 316/SAE 303)

Sample gas inlet conditions The analyzer module must not be used for measurement of ignit-able gas/air or gas/oxygen mixtures.

Temperature +5 to +50 °C

Inlet pressure pe ≤ 70 hPa

Outlet pressure Atmospheric pressure

Flow rate 4 to 20 l/h. Use a metering valve to set the flow rate.

Corrosive gases The presence of corrosive gases and catalyst poisons, e.g. halo-gens, gases containing sulfur and heavy-metal dust, leads to faster aging and/or destruction of the ZrO2 cell.

Flammable gases The analyzer is suitable for measuring flammable gases in general purpose environment. The concentration of flammable gases in the sample gas must not exceed 100 ppm.

Purge gas If case purging is selected, purging may only be carried out with air (not with nitrogen), since the ambient air is used as a refer-ence gas.

Note The trace oxygen analyzer module cannot be connected to the pneumatics module.

Gas connections The measuring chamber is connected to the sample gas inlet connection via a stainless steel tube (inlet side) and to the sam-ple gas outlet connection via a FPM hose (outlet side).

1 Sample gas inlet 3 mm Swagelok® 2 Sample gas outlet ⅛ NPT internal thread 7 Purge gas inlet housing (only for IP54 version)8 Purge gas outlet housing (only for IP54 version)

12

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— Thermal conductivity analyzer module Caldos25

Measurement principle Difference in thermal conductivity of various gases

Highly corrosion-resistant thermal conductivity analyzer, sample cells embedded in glass

Sample components and measurement ranges The Caldos25 is specifically designed for measurements of corro-sive gas components.

Sample components and smallest measurement ranges (examples) Sample component and associated gas

Smallest measurement range

Reference gas

H2 in N2 or air 0–0.5 vol.% Air (sealed)

SO2 in N2 or air 0–1.5 vol.% Air (sealed)

H2 in Cl2 0–0.5 vol.% Flowing

Measurement range quantity and limits 1 to 4 measurement ranges per sample component Ranges are factory-set per customer order.

Largest measurement range 0 to 100 vol.% or 0 vol.% to saturation Measurement ranges within ignition limits cannot be provided.

Measurement range switching ratio ≤ 1:20

Measurement ranges with suppressed zero-point Span at least 2 vol.%, depending on application



Zero drift ≤ 1 % of span per week




Influence effects Flow effect ≤ 1 to 5 % of span at a flow change of ±10 l/h. At an identical flow rate for test and sample gases, the flow rate effect is automati-cally compensated.

Associated gas effect Analyzer calibration should be based on an analysis of the sample gas. Measurement results can be greatly distorted by interfering components in complex (non-binary) gas mixtures.

Temperature effect Ambient temperature in permissible range at each point in the measurement range: ≤ 1 % of span per 10 °C, based on temperature at the time of calibration Thermostat temperature = 60 °C

Air pressure effect No effect in permissible operating condition range


Position effect < 1 % of span up to 10° deviation from horizontal orientation

Dynamic response Warm-up time 1.5 hours

90% response time Typical T90 = 10 to 20 sec; optional: T90 < 6 sec (applies to an analyzer unit with 1 analyzer module)

Calibration Zero-point calibration With sample component-free process gas or substitute gas

End-point calibration With process gas having a known sample gas concentration or with substitute gas


Materials in contact with the sample medium Analyzer Stainless steel 1.4305 (SAE 303), glass

Gas lines and connectors For sealed reference gas: Stainless steel 1.4305 (SAE 303); for flowing reference gas: PVC-C, FPM seals; for corrosive sample gas: PVC-C, FPM seals; if the sample gas con-tains NH3, FFKM seals are used.



Flow rate 10 to 90 l/h, max. 90 to 200 l/h for option T90 < 6 sec

Flowing reference gas Gas inlet conditions same as sample gas

Flammable gases The analyzer module is suitable for measuring flammable gases and vapors under atmospheric conditions (pabs ≤ 1.1 bar, oxygen content ≤ 21 vol.%). Temperature class: T4. The sample gas must not be explosive under normal conditions. If the sample gas is explosive in the event of a sample gas supply failure, then only seldom and briefly (in accordance with zone 2). Pressure in the sample gas path in normal operation pe ≤ 100 hPa; in case of a sample gas supply failure the pressure must not ex-ceed the maximum value pe = 500 hPa. Before using the analyzer module, the corrosion resistance against the specific sample gas must be checked. Housing purge with nitrogen should be provided when measur-ing flammable gases and vapors. Flame barriers can be used as an option (except for the “safety concept” version, see page 36). Pressure drop at the flame barriers approx. 40 hPa for a sample gas flow rate of 50 l/h. Material of the flame barriers: Stainless steel 1.4571 (SAE 316Ti).


Gas connections Standard version


Versions for corrosive sample gas or flowing reference gas


1 Sample gas inlet Caution! In versions for corrosive sample gas or flowing reference gas, gas ports 1 to 6 are made of PVC-C. Do not use metal adapters or hose nozzles!

2 Sample gas outlet 3 Purge gas inlet analyzer 4 Purge gas outlet analyzer 5 Reference gas inlet 2) 6 Reference gas outlet 2) 7 Purge gas inlet housing 1)



Pneumatics module 1) 2):11 Sample gas inlet12 End point gas inlet (with 3 solenoids) 13 Test gas / zero-point gas inlet (with 1 or 3 solenoids)14 Sample gas outlet – connect with sample gas inlet 11) Option2) Not in version for corrosive sample gas

12

3 4

7891012 11

1413

1 2

3 4

7891012 11

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6 5


— Thermal conductivity analyzer module Caldos27

Measurement principle Difference in thermal conductivity of various gases

Micromechanical silicon sensor with especially short T90 time

Sample components and measurement ranges Sample components and smallest possible measurement ranges (examples) Sample component and associated gas

Measurement ranges class 1 class 2

Standard gas 1)

for calibration

Ar in O2 0–20 0–2 vol.% Air, N2, O2

H2 in Ar 0–2.5 0–0.25 vol.% Air, N2, Ar

H2 in N2 or air 0–3 0–0.3 vol.% Air, N2

H2 in stack gas 0–5 0–0.5 vol.% Air, N2

CH4 in N2 0–20 0–2 vol.% Air, N2

CH4 in air 0–4 0–2 vol.% Air, N2

CO2 in N2 or air 0–30 0–3 vol.% Air, N2

Ar in N2 75–100 97.5–100 vol.% Air, N2, Ar

H2 in N2 90–100 97–100 vol.% N2, H2

99–100 2) vol.% N2, H2

CH4 in N2 90–100 99–100 vol.% N2, CH4

He in N2 90–100 97–100 vol.% He

1) Only for measurement ranges ≥ class 1 2) Daily zero-point check required

Sample components and measurement ranges for monitoring hydrogen-cooled turbo generators Sample component and associated gas Measurement range

CO2 in air 0–100 vol.%

H2 in CO2 100–0 vol.%

H2 in air 100–80/90 vol.%


Measurement range quantity and limits 1 to 4 measurement ranges per sample component. Range limits are freely adjustable. They are factory-calibrated for the largest possible measurement range.

Largest measurement range 0 to 100 vol.% or 0 vol.% to saturation, depending on measure-ment task. Measurement ranges within ignition limits cannot be provided.

Measurement range switching ratio ≤ 1:20

Measurement ranges with suppressed zero-point See the table above for spans

Stability These data apply only to measurement ranges ≥ class 2.

Linearity deviation ≤ 2 % of span


Zero drift ≤ 2 % of smallest possible measurement range per week

Sensitivity drift ≤ 0.5 % of smallest possible measurement range per week



Influence effects Flow effect ≤ 0.5 % of span at a flow change of ±10 l/h. At an identical flow rate for test and sample gases, the flow rate effect is automati-cally compensated.

Associated gas effect The knowledge of the sample gas composition is necessary for the analyzer configuration.

Temperature effect Ambient temperature in permissible range at each point in the measurement range: ≤ 0.5 % of span per 10 °C, based on temperature at the time of calibration Thermostat temperature = 60 °C

Air pressure effect ≤ 0.25 % of span per 10 hPa for the smallest possible ranges given; for larger spans, the effect is correspondingly lower. Option: Calibration for operating altitude over 2000 m


Position effect < 1 % of span up to 30° deviation from horizontal orientation

Dynamic response Warm-up time Approx. 30/60minutes for class 1/2 measurement ranges

90% response time T90 ≤ 2 sec for direct sample cell connection and sample gas flow of 60 l/h (applies to an analyzer unit with 1 analyzer module)

Calibration Zero-point calibration With test gas, measurement component-free process gas or sub-stitute gas

End-point calibration With test gas, process gas having a known sample gas concen-tration or substitute gas

Simplified calibration with standard gas For measurement ranges ≥ class 1, a single-point calibration can be performed with standard gas, since the zero- and end-points will not drift independently due to the sensor principle employed. This technique leaves out safety-related measurements. Depending on the measurement task involved, the zero- and end-points should be verified periodically (recommendation: once a year).


Materials in contact with the sample medium Analyzer Sample cell: Stainless steel 1.4305 (SAE 303); sensor: Gold, silicon oxi-nitride; seal: FFKM75



Flow rate Normally 10 to 90 l/h, minimum 1 l/h

Corrosive gases Consultation with ABB Analytical is required if the sample gas contains Cl2, HCl, HF, SO2, NH3, H2S or other corrosive components. FPM hoses should not be used if the sample gas contains NH3. In-stead, FFKM hoses should be used. In this case, the pneumatics module cannot be connected to the analyzer module.

Flammable gases The analyzer module is suitable for measuring flammable gases and vapors under atmospheric conditions (pabs ≤ 1.1 bar, oxygen content ≤ 21 vol.%). Temperature class: T4. The sample gas must not be explosive under normal conditions. If the sample gas is explosive in the event of a sample gas supply failure, then only seldom and briefly (in accordance with zone 2). Pressure in the sample gas path in normal operation pe ≤ 100 hPa; in case of a sample gas supply failure the pressure must not ex-ceed the maximum value pe = 500 hPa. Before using the analyzer module, the corrosion resistance against the specific sample gas must be checked. Housing purge with nitrogen should be provided when measur-ing flammable gases and vapors. Flame barriers can be used as an option (except for the “safety concept” version, see page 36). Pressure drop at the flame barriers approx. 40 hPa for a sample gas flow rate of 50 l/h. Material of the flame barriers: Stainless steel 1.4571 (SAE 316Ti).


Gas connections The sample cell is connected directly to the gas ports.

1 Sample gas inlet2 Sample gas outlet3 Purge gas inlet analyzer4 Purge gas outlet analyzer7 Purge gas inlet housing 1)

8 Purge gas outlet housing 1) (also with flow sensor)9 Pressure sensor 1

10 Pressure sensor 2

Pneumatics module 1):11 Sample gas inlet12 End point gas inlet (with 3 solenoids) 13 Test gas / zero-point gas inlet (with 1 or 3 solenoids)14 Sample gas outlet – connect with sample gas inlet 11) Option

12

3 4

7891012 11

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— FID analyzer module Fidas24

Measurement principle Flame-ionization detector

The analyzer module complies with the requirements for measur-ing instruments with flame ionization detection according to EN 12619.

Sample components and measurement ranges Sample components Hydrocarbons. The concentration of the gas components in the sample gas path must not exceed the temperature-dependent LEL. The analyzer temperature is 180 °C.

Number of sample components 4 sample components

Smallest measurement range 0–5 to 0–1500 mg org. C/m3 or 0–10 to 0–3000 ppm C1

Largest measurement range 0 to 80 g org. C/m3 or 0 to 15 vol.% C1 Larger measurement ranges on request.

Measurement range quantity and limits 1 to 4 measurement ranges Measurement ranges are factory-set per customer order. Small-est to largest measurement range ratio 1:300 to 1:1500, depend-ing on the configuration.

Stability The following data apply only if all influence factors (e.g. flow rate, temperature, atmospheric pressure) are constant. They apply to measurement ranges ≥ 50 mg org. C/m3, for smaller ranges these only apply if they are factory-set per customer order.

Linearity deviation ≤ 2 % of span to 5000 mg org. C/m3 this value applies in one (calibrated) measurement range

Repeatability ≤ 0.5 % of measurement range

Zero-point and sensitivity drift ≤ 0.5 mg org. C/m3 per week

Output fluctuation at zero-point (2 σ) ≤ 0.5 % of span at electronic T90 time = 20 sec

Detection limit (4 σ) ≤ 1 % of span at electronic T90 time = 20 sec

Influence effects Oxygen dependence ≤ 2 % of measured value for 0–21 vol.% O2 or ≤ 0.3 mg org. C/m3, the larger value applies

Temperature effect Ambient temperature in permissible range at zero-point and on sensitivity: ≤ 2 % of measured value per 10 °C or ≤ 300 ppb C1 per 10 °C

Power supply effect DC 24 V ± 5 %: ≤ 0.2 % of span or AC 230 V ± 10 %: ≤ 0.2 % of span

Dynamic response Warm-up time ≤ 2 hours

90% response time T90 < 1.5 s at sample gas flow = 80 l/h and electronic T90 time = 1 sec

Calibration Zero-point calibration With synthetic air or catalytically purified air or nitrogen, depend-ing on application

Sensitivity calibration With propane or another hydrocarbon (substitute gas) in air or nitrogen, depending on application

Materials in contact with the sample medium Analyzer, gas lines and connectors Stainless steel 1.4305 (SAE 303) and 1.4571 (SAE 316Ti), FPM, PTFE, FFKM

Operating gases and test gases Instrument air Quality per ISO 8573-1 class 2 (max. particle size 1 µm, max. parti-cle concentration 1 mg/m3, max. oil content 0.1 mg/m3, pressure dew point at least 10 °C below the lowest foreseeable ambient temperature) Inlet pressure pe = 4000 ± 500 hPa Flow rate typically approx. 1800 l/h (1200 l/h for air injector and approx. 600 l/h for housing purge), maximum approx. 2200 l/h (1500 l/h + 700 l/h)

Combustion air Synthetic air or catalytically purified air with an organic C content < 1 % span Inlet pressure pe = 1200 ± 100 hPa Flow rate < 20 l/h

Combustion gas Hydrogen (H2), grade 5.0, or H2/He mixture (40/60 %) Inlet pressure pe = 1200 ± 100 hPa Flow rate ≤ 3 l/h (H2) or approx. 10 l/h (H2/He) A flow limiting device must be provided on the hydrogen supply (see section “Safe operation of the gas analyzer”).

Test gases Zero-point calibration: Nitrogen, grade 5.0, or synthetic air or cat-alytically purified air Sensitivity calibration: Sample component or substitute gas component in nitrogen or air Inlet pressure pe = 1000 ± 100 hPa Flow rate 130 to 250 l/h


Sample gas inlet conditions The sample gas may not be explosive at any time.

The analyzer module must not be used for measurement of gases containing organometallic compounds, e.g. leaded gasoline addi-tives or silicone oils.

Temperature ≤ thermostat temperature (Thermostat temperature for sample gas path, detector and air injector ≤ 200 °C, factory-set to 180 °C)

Inlet pressure pabs = 800 to 1100 hPa


Flow rate Approx. 80 to 100 l/h at atmospheric pressure (1000 hPa)

Humidity ≤ 40 % H2O

Flammable gases The analyzer module can be used for measurement of flammable gases as long as the total flammable portion does not exceed 15 vol.% CH4 or C1 equivalents.

Safe operation of the gas analyzer The device concept ensures that a concentration of combustible gas or an explosive mixture of combustible gas and ambient air cannot occur in the interior of the gas analyzer during normal op-eration. The interior of the gas analyzer cannot be allocated to an (explosion protection) zone; an explosive gas mixture cannot es-cape to the outside.

The end user must make the following provisions to ensure safe operation of the gas analyzer: – The combustion gas flow rate must be limited to a maximum

of 10 l/h of H2 or 25 l/h of H2/He mixture. For this purpose, the end user has to provide suitable measures outside the gas an-alyzer.

– A shut-off valve must be installed in the combustion gas sup-ply line to increase the safety in the following operating states: Shutting down the gas analyzer, failure of the instrument air supply, leakage in the combustion gas feed path inside the gas analyzer. This shut-off valve should be installed outside the an-alyzer house near the combustion gas supply.

Gas and electrical connections

30 Power supply AC 115 or 230 V for heating of detector and sample gas inlet (4-pin male plug, connecting cable sup-plied)

31 Electrical connection to heated sample gas inlet (fixed)32 Test gas outlet33 Zero-point gas inlet34 End-point gas inlet35 Combustion air inlet36 Combustion gas inlet37 Instrument air inlet38 Exhaust outlet (male fitting for connecting the exhaust air

outlet tube: Stainless steel tube with terminal nut and clamping ring, outside diameter = 6 mm, included in the scope of supply and delivery of the gas analyzer. Permissi-ble maximum length of 30 cm; after that point the inner di-ameter of the exhaust line should be increased to ≥ 10 mm.)

39 Sample gas inlet, heated or unheated (Threaded connection for PTFE or stainless steel tubing with a 6-mm outer diame-ter)

40 Pressure compensation opening with protection filter24 V External power supply DC 24 V (4-pin male plug)Bus System bus (3-pin female plug)

Sample gas line connection To heated sample gas inlet: – In wall-mount housing: bottom and right – In 19-inch housing: back, top and bottom To unheated sample gas inlet: – In wall-mount and 19-inch housing: back

4037

36

35

3433

32

30 31 3839


— FID analyzer module Fidas24 NMHC

Measurement principle Non-methane flame-ionization detector (NMHC = non-methane hydrocarbons)

The analyzer module complies with the requirements for measur-ing instruments with flame ionization detection according to EN 12619.

A non-methane converter is used in the analyzer module for the measurement of CH4.

Sample components and measurement ranges Sample components Hydrocarbons. The CH4/NMHC ratio must be in the 1:9 to 9:1 range. Maximum concentration CH4: 26500 mg org. C/m3 or 50000 ppm C1. Maximum concentration NMHC: 5000 mg org. C/m3 or 9330 ppm C1. The concentration of the gas components in the sample gas path must not exceed the temperature-dependent LEL. The analyzer temperature is 180 °C.

Number of sample components 2 sample components: CH4 and THC. The calculated non-methane portion of the hydrocarbons is output as 3rd component NMHC.

Smallest measurement range 0–5 to 0–1500 mg org. C/m3 or 0–10 to 0–3000 ppm C1

Largest measurement range CH4 and THC 0–50 to 0–25000 mg org. C/m3 or 0–100 to 0–50000 ppm C1

Largest measurement range NMHC 0–5000 mg org. C/m3 or 0–10000 ppm C1

Measurement range quantity and limits 1 to 4 measurement ranges Measurement ranges are factory-set per customer order.

Stability The following data apply only if all influence factors (e.g. flow rate, temperature, atmospheric pressure) are constant. They apply to measurement ranges ≥ 50 mg org. C/m3, for smaller ranges these only apply if they are factory-set per customer order.

Linearity deviation ≤ 2 % of span to 5000 mg org. C/m3 this value applies in one (calibrated) measurement range

Repeatability ≤ 0.5 % of measurement range

Zero-point and sensitivity drift ≤ 0.5 mg org. C/m3 per week

Output fluctuation at zero-point (2 σ) ≤ 0.5 % of span at electronic T90 time = 20 sec

Detection limit (4 σ) ≤ 1 % of span at electronic T90 time = 20 sec

Influence effects Oxygen dependence ≤ 2 % of measured value for 0–21 vol.% O2 or ≤ 0.3 mg org. C/m3, the larger value applies

Temperature effect Ambient temperature in permissible range at zero-point and on sensitivity: ≤ 2 % of measured value per 10 °C or ≤ 300 ppb C1 per 10 °C

Power supply effect DC 24 V ± 5 %: ≤ 0.2 % of span or AC 230 V ± 10 %: ≤ 0.2 % of span

Dynamic response Warm-up time ≤ 2 hours

90% response time T90 < 2.5 s via bypass, T90 < 3 s via converter at sample gas flow = 80 l/h and electronic T90 time = 1 sec

Switchover time Between bypass and converter typically 20 s, depending on measurement range

Converter Converter service life The catalyst is a consumable material. Its service life depends on the concentration of the converted hydrocarbons. Catalyst poi-sons (e.g. SO2, HCl, H2S, halogenated hydrocarbons, heavy metals) will shorten the converter service life. Their respective concentra-tion should always be < 20 mg/m3. It is recommended to test the converter function once a year.

Calibration Zero-point calibration With synthetic air or catalytically purified air, depending on appli-cation

Sensitivity calibration With methane or propane in air, depending on application

Materials in contact with the sample medium Analyzer, gas lines and connectors Stainless steel 1.4305 (SAE 303) and 1.4571 (SAE 316Ti), FPM, PTFE, FFKM

Operating gases and test gases Instrument air Quality per ISO 8573-1 class 2 (max. particle size 1 µm, max. parti-cle concentration 1 mg/m3, max. oil content 0.1 mg/m3, pressure dew point at least 10 °C below the lowest foreseeable ambient temperature), inlet pressure pe = 4000 ± 500 hPa, flow rate typi-cally approx. 1800 l/h (1200 l/h for air injector and approx. 600 l/h for housing purge), maximum approx. 2200 l/h (1500 l/h + 700 l/h)

Combustion air Synthetic air or catalytically purified air with an organic C content < 1 % span, inlet pressure pe = 1200 ± 100 hPa, flow rate < 20 l/h


Combustion gas Hydrogen (H2), grade 5.0, or H2/He mixture (40/60 %), inlet pres-sure pe = 1200 ± 100 hPa, flow rate ≤ 3 l/h (H2) or approx. 10 l/h (H2/He). A flow-limiting device must be provided on the hydrogen supply (see section “Safe operation of the gas analyzer”).

Test gases Zero-point calibration: Synthetic air or catalytically purified air. Sensitivity calibration: Sample component CH4: CH4 in air, sample component THC: C3H8 in air or CH4 in air. Inlet pressure pe = 1000 ± 100 hPa, flow rate 130 to 250 l/h

Test gases for converter effectiveness testing CH4 or C2H6 in air (separate test gas bottles), connection via by-pass, inlet pressure pe = 1000 ± 100 hPa, flow rate 130 to 250 l/h

Sample gas inlet conditions The sample gas may not be explosive at any time.

The analyzer module must not be used for measurement of gases containing organometallic compounds, e.g. leaded gasoline addi-tives or silicone oils.

Temperature ≤ thermostat temperature (Thermostat temperature for sample gas path, detector and air injector ≤ 200 °C, factory-set to 180 °C)

Inlet pressure pabs = 850 to 1100 hPa


Flow rate Approx. 80 to 100 l/h at atmospheric pressure (1000 hPa)

Humidity ≤ 40 % H2O

Flammable gases The analyzer module can be used for measurement of flammable gases as long as the total flammable portion does not exceed 5 vol.% CH4 or C1 equivalents.

Safe operation of the gas analyzer The device concept ensures that a concentration of combustible gas or an explosive mixture of combustible gas and ambient air cannot occur in the interior of the gas analyzer during normal op-eration. The interior of the gas analyzer cannot be allocated to an (explosion protection) zone; an explosive gas mixture cannot es-cape to the outside.

The end user must make the following provisions to ensure safe operation of the gas analyzer: – The combustion gas flow rate must be limited to a maximum

of 10 l/h of H2 or 25 l/h of H2/He mixture. For this purpose, the end user has to provide suitable measures outside the gas an-alyzer.

– A shut-off valve must be installed in the combustion gas sup-ply line to increase the safety in the following operating states: Shutting down the gas analyzer, failure of the instrument air supply, leakage in the combustion gas feed path inside the gas analyzer. This shut-off valve should be installed outside the an-alyzer house near the combustion gas supply.

Gas and electrical connections

30 Power supply AC 115 or 230 V for heating of detector and sample gas inlet (4-pin male plug, connecting cable sup-plied)

31 Electrical connection to heated sample gas inlet (fixed)32 Test gas outlet33 Zero-point gas inlet34 End-point gas inlet35 Combustion air inlet36 Combustion gas inlet37 Instrument air inlet38 Exhaust outlet (Male fitting for connecting the exhaust air

outlet tube: Stainless steel tube with terminal nut and clamping ring, outside diameter = 6 mm, included in the scope of supply and delivery of the gas analyzer. Permissi-ble maximum length of 30 cm; after that point the inner di-ameter of the exhaust line should be increased to ≥ 10 mm.)

39 Sample gas inlet, heated or unheated (Threaded connection for PTFE or stainless steel tubing with a 6-mm outer diame-ter)

40 Pressure compensation opening with protection filter24 V External power supply DC 24 V (4-pin male plug)Bus System bus (3-pin female plug)

Sample gas line connection To heated sample gas inlet: – In wall-mount housing: bottom and right – In 19-inch housing: back, top and bottom To unheated sample gas inlet: – In wall-mount and 19-inch housing: back

4037

36

35

3433

32

30 31 3839


— Laser analyzer module LS25

Measurement principle The LS25 laser analyzer module is based on a measuring principle called single-line spectroscopy. One single target gas absorption line with no interference is chosen in the near infrared spectral range. A single mode diode laser operating around room temper-ature scans this single absorption line. A detector diametrically opposite detects the light and the absorption caused only by the target gas molecules. Once the absorption by the target gas mol-ecules is detected, the gas concentration is calculated. Automatic corrections for temperature and pressure variations are included.

Sample components and measurement ranges The LS25 laser analyzer module has one physical measurement range per sample component. The indicated measurement range can be freely calibrated within the physical measurement range. The smallest detection limits and corresponding measurement ranges are shown in the table below:

Sample component

Min. measurement range

Max. abs. pressure

Max. temperature

O2 0– 1 vol.% 10 bar 1500 °C

NH3 0– 20 ppm 1.5 bar 500 °C

HCl 0– 5 ppm 1.5 bar 400 °C

HF 0– 3 ppm 1.5 bar 300 °C

H2S 0– 300 ppm 1.5 bar 300 °C

H2O (ppm) 0– 30 ppm 1.5 bar 1300 °C

H2O (vol.%) 0– 1 vol.% 1.5 bar 1500 °C

CO (ppm) 0– 20 ppm 1.5 bar 500 °C

CO (vol.%) 0– 1 vol.% 1.5 bar 600 °C

CO2 (ppm) 0– 100 ppm 1.5 bar 300 °C

CO2 (vol.%) 0– 1 vol.% 1.5 bar 1500 °C

NO 0– 1500 ppm 1.5 bar 300 °C

N2O 0– 500 ppm 1.5 bar 200 °C

HCN 0– 30 ppm 1.5 bar 300 °C

CH4 0– 1 vol.% 1.5 bar 500 °C

NH3 + H2O

0– 20 ppm 0– 2 vol.%

1.5 bar 500 °C

HCl + H2O

0– 5 ppm 0– 5 vol.%

1.5 bar 400 °C

HF + H2O

0– 3 ppm 0– 2 vol.%

1.5 bar 300 °C

CO (vol.%) + CO2 (vol.%)

0– 1 vol.% 0– 1 vol.%

1.5 bar 600 °C

HCl + CH4

0– 300 ppm 0– 1 vol.%

1.5 bar 400 °C

CO (ppm) + CH4

0– 20 ppm 0– 100 ppm

1.5 bar 500 °C

CO (ppm) + H2O (vol.%)

0– 100 ppm 0– 5 vol.%

1.5 bar 1500 °C

O2 + temp. 0– 1 vol.% 1.5 bar 1500 °C

Other sample components on request. All specifications refer to an optical path length (OPL) of 1 meter, tested in ABB’s test/calibration jig. The standard optical path length ranges from 0.5 to 6 m (larger OPL on request). Applica-tion-dependent variations may occur. To obtain minimum meas-urement ranges in some cases additional measures have to be

taken: Low level O2 and H2O require instrument and process purg-ing with nitrogen. Actual detection limit for a specific application will depend on the gas conditions (pressure, temperature and gas composition) and optical path length. If more than one min. measurement range is shown, there are different instrument ver-sions available. Min. measurement range, max. pressure and max. temperature cannot necessarily be realized simultaneously. The maximum pressure and temperature given are physical (spectroscopic) lim-its. Applications with increased temperature or pressure or with toxic or flammable gas may require additional equipment.

Measurement range quantity 1 range per sample component, 1 x transmission

Largest measurement range Largest measurement range is generally 100 times the minimum measurement range for the same conditions. Larger measure-ment ranges are normally possible by adaptation of measuring path and choice of a weaker absorption line.


Repeatability ± Detection limit or ± 1 % of reading, whichever is greater

Zero drift < 2 % of smallest possible measurement range per 6 months

Span drift < 4 % of measurement range per 6 months

Output fluctuation (2 σ) ≤ 0.5 % of smallest measurement range

Detection limit (4 σ) ≤ 1 % of smallest measurement range

Influence effects Flow effect No effect on the measurement, but the flow will determine the amount of purge gas needed.

Associated gas effect/cross sensitivity No cross sensitivity within normal operation conditions.

Temperature effect – Ambient temperature in permissible range: No significant ef-

fect – Gas temperature effect: Typically ≤ 2 % of measured value per

10 °C (dependent on type of gas and gas conditions). For large variations in gas temperature (> ±20 °C) separate temperature measurement for compensation is recom-mended.

Pressure effect – At zero-point: No effect. – Automatic compensation for large variations in sample gas

pressure by measurement of absorption line width, alterna-tively by input from pressure sensor.



Dynamic response Warm-up time Approx. 1 hour

Response time Less than 2 seconds without signal averaging

Calibration Maintenance interval Depending on application and dust load. Typically between every 6 months and once a year (no consumables required).

Zero-point check With inert gas, e.g. nitrogen, or with ambient air free of the sam-ple component. The zero point cannot be calibrated. Due to the measurement principle, there is no zero-point drift.

Calibration With test gas and a flow-through test cell. Calibration interval typically between every 6 months and once a year. Recommended calibration interval will be stated in calibration certificate that ac-companies delivery.

Materials in contact with the process gas Purge and alignment unit 316 SS

Windows BK7 glass, optional: fused silica, for HF: sapphire

Mounting Available flanges DN50/PN10, DN80/PN10; ANSI 2/150 lbs, ANSI 2/300 lbs, ANSI 3/150 lbs, ANSI 3/300 lbs

Alignment tolerances Flanges parallel within 1.5°

Purging of windows Dry and oil-free pressurized air or gas, or by fan

Gas ports for purging Standard: ⅜-inch hose nozzle for hoses with 10 mm inner diame-ter. See page 32 for connection drawing.

Weight Transmitter unit plus flange with purging unit: 9.5 (6.3 + 3.2) kg Receiver unit plus flange with purging unit: 7.2 (4.0 + 3.2) kg Flow-through test cell: 3.8 kg

Dimensions See page 33

Electrical connections on transmitter unit Connection to central unit Ethernet 10/100BASE-T, RJ45 connector Cable length: Standard 15 m, max. 100 m

Connection to receiver unit 15-pin female Sub-D connector Cable length: Standard 5 m, max. 150 m

Power supply, external pressure and temperature signals 15-pin male Sub-D connector; Cable length laser unit–power supply: Standard 3 m, max. 100 m; Cable length power supply–plug: 3 m

Service computer RS232, 9-pin female Sub-D connector; Ethernet

Connection drawing See page 33

Process gas properties Maximum process gas temperature and pressure are given in the “Sample components and measurement ranges” table. Quantifi-cation of dust/particle concentration is necessary in order to de-termine max OPL. The maximum dust concentration must be checked by ABB Analytical.

Purge gas requirements The purge gas should not contain any sample gas components and must be oil- and dust-free.

Power supply Input voltage DC 24 V ± 5 % from an external power supply unit AC 115/230 V (part of the delivery for general-purpose applications)

Power consumption Approx. 20 W

Installation site requirements The mounting location strongly influences the measurement re-sult. The measurement gas must be well stirred at the selected location to produce a representative measurement result. Strati-fication in the measurement gas path results in erroneous meas-urement. If the measurement gas is charged with dust, the LS25 must be mounted at right angles to the process gas flow.

Explosion-proof versions The AO2000-LS25 Ex analyzer module is suited for use in areas in which explosive atmospheres caused by vapors, gases, mists, or air/dust mixtures are likely to occur. The external power supply is not approved for installation in hazardous areas.

Version for use in zone 2

Marking II 3 G Ex nA nC [op is Ga] IIC T5 1) Gc, −20°C ≤ Tamb ≤ +55°C II 3 D Ex tc [op is Da] IIIC T100°C Dc, −20°C ≤ Tamb ≤ +55°C

1) T4 for special applications

Housing protection type IP66

Version for use in Class 1, Division 2 – CSA

The AO2000-LS25 Ex analyzer module is certified for use in haz-ardous areas Class 1, Division 2, Groups A, B, C and D, Tempera-ture Code T4, ambient temperature max. +55 °C. Certificate No. 1105720


— … Laser analyzer module LS25

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— Electrochemical oxygen sensor

Measurement principle Electrochemical oxygen sensor


Measurement range quantity and limits 1 to 2 measurement ranges Adjustable from 0–5 vol.% O2 to 0–25 vol.% O2



Zero drift Stable over long-term due to absolute zero point

Sensitivity drift ≤ 1 % of the measurement range per week

Output fluctuation (2 σ) ≤ 0.2 % of the measurement range at electronic T90 time (static/dynamic) = 5/0 sec

Detection limit (4 σ) ≤ 0.4 % of the measurement range at electronic T90 time (static/dynamic) = 5/0 sec

Influence effects Flow effect Flow rate in the 20 to 100 l/h range: ≤ 2 % of the measurement range

Temperature effect Ambient temperature in permissible range: ≤ 0.2 vol.% O2 per 10 °C

Air pressure effect – At zero-point: No effect – On sensitivity with no pressure correction:

≤ 1 % of the measured value per 1 % air pressure change – On sensitivity with pressure correction:

≤ 0.2 % of the measured value per 1 % air pressure change Pressure correction is only possible if the oxygen sensor is connected to an analyzer module with an integral pressure sensor.

Power supply effect Voltage and frequency in the permissible range: ≤ 0.2 % of span

Dynamic response 90% response time T90 ≤ 30 sec, depending on sample gas flow and system layout

Calibration Zero-point calibration The oxygen sensor zero is not calibrated since it is fundamentally stable.

End-point calibration With ambient air at 20.96 vol.% O2

Materials in contact with the sample medium Sensor: Polystyrol-ABS, PTFE, FPM; Housing body: PVC-U, FPM seals; Gas ports: Stainless steel 1.4571 (SAE 316Ti)

Sample gas inlet conditions The oxygen sensor must not be used for measurement of flam-mable gases and ignitable gas/air or gas/oxygen mixtures.

Temperature The sample gas dew point should be at least 5 °C below the am-bient temperature throughout the sample gas path. Otherwise, a sample gas cooler or condensate trap is required.

Moisture content H2O dew point ≥ 2 °C The oxygen sensor should not be used with dry sample gas.

Inlet pressure pe = 2 to 500 hPa



Associated gas The oxygen sensor should not be used if the associated gas con-tains the following components: H2S, chlorine or fluorine com-pounds, heavy metals, aerosols, mercaptans, and alkaline compo-nents.

Notes The oxygen sensor is always associated with an analyzer module and must be installed in the same housing with that analyzer module.

The oxygen sensor cannot be used with the following analyzer modules: – Limas21 UV, Limas21 HW with stainless steel, PFA or PTFE gas

lines – Fidas24, Fidas24 NMHC – Analyzer modules for measuring corrosive gases – Analyzer modules in category 2G


— Pneumatics module

Test gas supply Type One or three 3/2-way solenoid valves

Power consumption Approx. 3 W per solenoid valve

Materials in contact with the sample medium PVDF, FPM, aluminum, stainless steel 1.4305 (SAE 303)

Fine filtration Type Disposable filter with borosilicate glass microfiber filter element

Retention rate 99.99 % for particles > 0.1 µm

Materials in contact with the sample medium Polyamide, borosilicate glass with PVDF binder

Gas supply Type Magnetic piston pump

Feed rate Max. 60 l/h, depending on analyzer module and inlet/outlet pres-sure

Flow rate Adjustable

Power consumption Approx. 10 W

Materials in contact with the sample medium PVDF, EPDM, stainless steel 1.4571 (SAE 316Ti)

Flow monitoring Type Miniature flow sensor

Readout and limit value monitoring Configurable

Materials in contact with the sample medium Al2O3, silicon, gold, GFK

Pressure monitoring Pressure sensor (Option) for additional monitoring tasks, e.g. pressure measure-ment in the second gas path of the Uras26 analyzer module

Sample gas inlet conditions The pneumatics module must not be used for measurement of flammable gases and ignitable gas/air or gas/oxygen mixtures.

Temperature +5 to +45 °C The sample gas dew point should be at least 5 °C below the am-bient temperature throughout the sample gas path. Otherwise, a sample gas cooler or condensate trap is required.

Inlet pressure pe = −80 to +20 hPa


Corrosive gases Corrosive associated gas components and aerosols must be cooled or undergo prior absorption.

Notes The pneumatics module is always associated with an analyzer module and must be installed in the same housing with that ana-lyzer module.

The pneumatics module cannot be used when stainless steel tubes are used for the internal gas lines.

The pneumatics module cannot be used with the following ana-lyzer modules: – Limas21 UV, Limas21 HW with stainless steel, PFA or PTFE gas

lines – Fidas24, Fidas24 NMHC – Analyzer modules in category 2G


— Explosion protected versions in category 3G

Version in category 3G for measurement of flamma-ble and non-flammable gases (“Safety concept”) The “safety concept” gas analyzers include: – Uras26 in the version with safety cell and purged sample cell

windows – Magnos206, Caldos25 and Caldos27 in the version with direct

sample cell connection and purged thermostat housing.

Monitoring of the purge gas flow rate is a feature of the “safety concept”. It is fully integrated into the gas analyzer, together with the controls and signal processing.

The version complies with Directive 2014/34/EU (ATEX Directive). There are the following explosion protection measures in the gas analyzer: – Non-arcing assemblies and components/non-hot components/

sealed (arcing) devices per EN 60079-15 and – Simplified positive pressure containment per EN 60079-2.

Marking II 3G Ex nA pyb II T4 Gc


Sample gas inlet conditions

Sample gas Flammable and non-flammable gases and vapors – Under atmospheric conditions (pabs ≤ 1.1 bar, oxygen content

≤ 21 vol.%), – Temperature class T4, – Not potentially explosive under normal conditions, – If potentially explosive in the event of a fault, then only seldom

and briefly (in accordance with zone 2). If the sample gas is a mixture only of oxygen and flammable gases and vapors, it must not be explosive under any conditions. As a rule, this can be achieved by limiting the oxygen content to a maximum of 2 vol.%. Flammable gases and vapors that are explosive under the condi-tions encountered in analysis even when oxygen is excluded should be present in the mixture only in concentrations that are not critical to safety.

Pressure At sample gas inlet: positive pressure pe ≤ 3 hPa, at sample gas outlet: atmospheric

Flow rate Max. 40 l/h

Inert gas curtain/purge gas/(Simplified) pressurized enclosure

Purge gas Inert gas (nitrogen)

Pressure Positive operating pressure pe ≥ sample gas pressure + 0.5 hPa

Flow rate During operation: 15 to 20 l/h, during initial purge: 15 to 50 l/h

Initial purge Manually controlled, initial purge duration: Uras26: 1.6 minutes at min. 15 l/h Magnos206, Caldos25, and Caldos27: 18 minutes at min. 15 l/h or 6 minutes at min. 50 l/h

Alarm When flow rate drops below a minimum value of 15 l/h (corre-sponds to approx. 7 hPa) and when flow rate exceeds a maximum value of 50 l/h (corresponds to approx. 60 hPa)

Version in category 3G for measurement of non-flammable gases The analyzer modules Uras26, Magnos206, Magnos27, Caldos25 und Caldos27 are suitable for measuring non-flammable gases. The analyzer modules are mounted in the central unit housing or in a separate housing (either wall-mount or 19-inch rack unit).

The version complies with the Directive 2014/34/EU (ATEX di-rective). The gas analyzer is protected by provisions according to EN 60079-15 (non-arcing electrical equipment, sealed arcing de-vices).

In undisturbed operation, there cannot be any sparking, arcing or impermissible temperatures inside the device. During operation, all unused gas ports should be plugged.

Marking II 3G Ex nA nC IIC T4 Gc



Gas connections “Safety concept” Uras26

1 Sample gas inlet gas path 1 2 Sample gas outlet gas path 1 3 Purge gas inlet sample cell windows “Analyzer purge in” 4 Purge gas inlet housing 5 Purge gas outlet housing 6 Purge gas outlet flow rate monitor “Analyzer purge out” 7 Sample gas outlet gas path 2 8 Sample gas inlet gas path 2 9 Pressure sensor (option)

Magnos206 Caldos25, Caldos27

1 Sample gas inlet 1 Sample gas inlet2 Sample gas outlet 2 Sample gas outlet3 Purge gas inlet thermostat chamber “Analyzer purge in” 3 Purge gas inlet thermostat chamber “Analyzer purge in”4 Purge gas outlet thermostat chamber (rigid tubed with 13) 4 Purge gas outlet thermostat chamber (rigid tubed with 13)7 Purge gas inlet housing 7 Purge gas inlet housing8 Purge gas outlet housing 8 Purge gas outlet housing9 Pressure sensor 1 9 Pressure sensor 1

10 Pressure sensor 2 10 Pressure sensor 211 not used, sealed 11 not used, sealed12 not used, sealed 12 not used, sealed13 Purge gas inlet flow rate monitor (rigid tubed with 4) 13 Purge gas inlet flow rate monitor (rigid tubed with 4)14 Purge gas outlet flow rate monitor “Analyzer purge out” 14 Purge gas outlet flow rate monitor “Analyzer purge out”

9

8

7

6 5 4 3

2

1

1 2

3 4

13 14

12 11 10 9 8 7

12

3 4

7891012 11

1413


— General data

Display and operation Display Backlit graphics display, 320 x 240-pixel resolution

Measured value display Digits with unit and bar graph; simultaneous display of up to six measured values, configurable

Units of measure Selectable in physical units, e.g. ppm, vol.%, mg/m3 or g/m3, as well as in % of span or mA

Digital value resolution Better than 0.2 % of span

Status indication Green LED: Power supply on Yellow LED: Maintenance request Red LED: Failure

Status messages Plain text

Operation Panel with six softkeys, two cancel keys and 10-digit keypad; menu-driven interface, various languages available

Measuring range switch-over and feedback There are three ways of executing the measuring range switch-over: – Manually on the gas analyzer – Automatically (autorange) by means of appropriate configured

switch-over thresholds – Externally controlled via appropriately configured digital in-

puts. The measuring range feedback can be implemented via appropri-ately configured digital outputs; it is independent of the selected type of measuring range switch-over.

Limit value monitoring Limit values can be set during the gas analyzer configuration. The limit value signals (alarms) are output via digital outputs.

Housing Versions 19-inch housing (model AO2020) or Wall-mount housing (model AO2040)

Housing protection type IP65 without power supply and without display/control unit, IP54 with display/control unit and connection box, IP20 without connection box per EN 60529

Housing materials Housing: stainless steel 1.4016 (SAE 430), module rear panel: alu-minum, keypad sheet: Polyester

Housing color Light gray (RAL 7035), basalt gray (RAL 7012)

Weight Analyzer unit with one analyzer module: 18 to 23 kg

Dimensions See page 45

Housing purge Housing purge is possible with IP54 version with connection box. Purge version can be fitted with screwed cable glands (per EN) or with conduit connections (per CSA). Purge gas flow during oper-ation max. 20 l/h (Fidas24, Fidas24 NMHC: approx. 300 l/h), purge gas pressure pe = 2–4 hPa. The purge gas should not con-tain any sample gas components.

Pressure sensor Use Standard: with Uras26, Limas21 UV, Limas21 HW, Caldos27; option: with Magnos206, Magnos28 and Magnos27; not necessary with Caldos25, Fidas24, ZO23

Working range pabs = 600–1250 hPa

Materials in contact with the sample medium Silicone gel, plastics, FPM (Fluorocarbon rubber)

Sample gas composition The pressure sensor must not be connected to the sample gas path when the sample gas is corrosive, flammable or explosive.

Gas connections Layout Gas ports on back (19-inch rack housing) or bottom (wall-mount housing) of the analyzer module

Design ⅛ NPT internal threads for commercially available adapters, e.g. Swagelok®, unless other versions are specified in the technical data of the individual analyzer modules.

Electrical connections Central unit Power supply: 3-pin plug per EN 60320/C14, connecting cable supplied; Ethernet: Two 8-pin RJ45 plugs; System bus: 3-pin female plug

Analyzer modules External power supply: 4-pin male plug; Heating of detector and sample gas inlet (FID analyzer modules): 4-pin male plug, connecting cable supplied; System bus: 3-pin female plug

Electrical safety Tested per EN 61010-1:2010

Protection class Central unit with electronics module (power supply): I, Analyzer modules without electronics module (power supply): III

Overvoltage category/pollution degree Power supply: II/2

Safe isolation The power supply is galvanically isolated from other circuits by means of reinforced or double insulation. Protective extra-low voltage (PELV) on low-voltage side


Electromagnetic compatibility Noise immunity Tested per EN 61326-1:2013. Inspection severity: Industrial area, fulfills at least the rating to table 2 of EN 61326.

Emitted interference Tested per EN 61326-1:2013. Limit value class B for interference field strength and interference voltage is met.

Mechanical stress Transport Vibration test per EN 60068-2-6:1996. Shock test per EN 60068-2-27:1995. In its original packaging, the gas analyzer will withstand normal shipping conditions.

Installation site requirements Installation location The gas analyzer is intended for indoor installation only. Altitude above 2000 m on request.

Vibration Analyzer unit only: Uras26: Max. ±0.04 mm at 5 to 55 Hz, 0.5 g at

55 to 150 Hz, slight transient effect on sample value in the region of the beam modulation frequency

Limas21 UV: Max. ±0.04 mm at 5 to 55 Hz, 0.5 g at 55 to 150 Hz

Limas21 HW: Max. ±0.04 mm/0.5 g at 5 to 150 Hz Magnos206: Max. ±0.04 mm at 5 to 20 Hz Magnos28: Max. ±0.04 mm at 5 to 20 Hz Magnos27: Max. ±0.04 mm at 5 to 60 Hz ZO23: Max. ±0.04 mm at 5 to 55 Hz, 0.5 g at

55 to 150 Hz Caldos25: Max. ±0.04 mm at 5 to 30 Hz Caldos27: Max. ±0.04 mm at 5 to 55 Hz, 0.5 g at

55 to 150 Hz Fidas24: Max. 0.5 g, max. 150 Hz Fidas24 NMHC: Max. 0.5 g, max. 150 Hz LS25: Max. ±0.6 mm around the optical axis,

max. 500 Hz

Analyzer unit installed in cabinet (analyzer system): Max. acceler-ation 0.01 ms−2 in a frequency range of 0.1 to 200 Hz. For compli-ance with the metrological data, a vibration damped/decoupled installation of the gas analyzer may be necessary in accordance with the vibration effects at the installation site.

Ambient temperature Operation: When installed in housing

with electronics module

without electronics module

Uras26: +5 to +40 °C +5 to +45 °C Limas21 UV: +5 to +40/45 °C

with/w/o I/O cards +5 to +45 °C

Limas21 HW: +15 to +35 °C +15 to +35 °C Magnos206: +5 to +45 °C +5 to +50 °C Magnos28: +5 to +45 °C +5 to +50 °C Magnos27: +5 to +45 °C +5 to +45 °C,

+5 to +50 °C 1) ZO23: +5 to +45 °C +5 to +45 °C Caldos25: +5 to +45 °C +5 to +45 °C Caldos27: +5 to +45 °C +5 to +50 °C Fidas24: +5 to +45 °C +5 to +45 °C Fidas24 NMHC: +5 to +40 °C +5 to +40 °C LS25: −20 to +55 °C, no direct solar irradiationOxygen sensor: +5 to +40 °C in 19-inch housing,

+5 to +35 °C in wall-mount housing Central unit without analyzer module:

+5 to +55 °C

Storage and transport: −25 to +65 °C, oxygen sensor: −20 to +60 °C

1) With direct sample cell connection and when installed in hous-ing without Uras26

Relative humidity < 75 %, no condensation

Climate class 3K3 for IP20 housing (non-condensing), 3K4 for IP54 housing (condensing) per EN 60721-3-3

Air circulation For sufficient air circulation, multiple housings in a 19-inch rack must be installed with a separation of at least one height unit be-tween housings.


— … General data

Power supply Power supply unit

Input voltage AC 100 to 240 V, − 15 %, + 10 %, max. 2.2 A, 50 to 60 Hz ± 3 Hz

Power consumption Max. 187 VA

Output voltage DC 24 V ± 3 % to supply the electronics module (see page 41) and one analyzer module installed in the central unit or (optionally) one external analyzer module

Fidas24, Fidas24 NMHC: Heating of detector and sample gas inlet

Input voltage AC 115 V or 230 V, ± 15 % (max. AC 250 V), 47 to 63 Hz

Power consumption Fidas24: 125 VA for detector 125 VA for sample gas inlet (option) Fidas24 NMHC: Approx. 200 VA for detector 125 VA for sample gas inlet (option)

Analyzer modules

Input voltage DC 24 V ± 5 %

Power consumption Uras26: Max. 95 W Limas21 UV: Max. 100 W Limas21 HW: Max. 100 W Magnos206: Max. 50 W Magnos28: Max. 50 W Magnos27: Max. 35 W ZO23: Max. 35 W Caldos25: Max. 25 W Caldos27: Max. 17 W Fidas24: Max. 40 W Fidas24 NMHC: Max. 40 W LS25: Approx. 20 W

Note regarding the analyzer module performance characteristics The analyzer module performance characteristics indicated apply only when operated in conjunction with the central unit. They have been determined according to IEC 61207-1:2010 “Expression of performance of gas analyzers – Part 1: General”. They are based on operation at atmospheric pressure (1013 hPa) and ni-trogen as the associated gas. Compliance with these characteris-tics when measuring other gas mixtures can only be assured if their composition is known. The physical detection limit is the lower limit of the performance characteristics relative to the measuring range span.


— Electronics module

Processing of measured values and signals Processor system with buffered real-time clock and non-volatile memory for firmware and device data.

Software updates can be obtained via the Ethernet interface.

I/O modules Number of Slots 5 slots (see “Electrical connections”)

Technical data See pages 42 to 44

Notes regarding conductor section – The maximum capacity of terminals for stranded or solid con-

ductors is 1 mm2 (17 AWG). – The stranded conductor may be tinned on the tip or twisted

for simplified connection. – When using wire end ferrules the total section should not ex-

ceed 1 mm2, i.e. the maximum stranded conductor section is 0.5 mm2. The Weidmüller PZ 6/5 crimping tool must be used for crimping the ferrules.

Interfaces Ethernet To connect the gas analyzer to Ethernet networks. TCP/IP proto-col and Modbus TCP/IP protocol via 10/100/1000BASE-T inter-face. Electrical connections: Two 8-pin RJ45 plugs

System bus Internal bus for communication between the gas analyzer’s func-tional units. Electrical connections: 3-pin female plug

Power supply Input voltage DC 24 V ± 3 % from the built-in power supply (see page 40)

Power consumption approx. 15 W without I/O modules

Electrical connections

-X01 Power supply connection

-X07 System bus connection

-X08, -X09

Ethernet 10/100/1000BASE-T interfaces

-X20 to -X29

I/O modules (5 slots), options:– Profibus module – Modbus module – Digital I/O module – 2-way analog output module– 4-way analog output module– 4-way analog input moduleConnection diagrams see pages 42 to 44

Note The drawing shows an example for the I/O mod-ules equipment.

1

6

1

6

1

6

-X29

-X27

-X25

-X26

-X24

-X22

-X20

-X28

-X23

-X21-X07

-X01

-X08 -X09


— I/O modules

Profibus module Application Integration of AO2000 into PROFIBUS PA and PROFIBUS DP net-works for transfer of measured values and status signals as well as analog inputs, digital inputs and digital outputs. Digital data transmission certified according to guideline VDI 4201, Sheets 1 and 2.

Electrical connections RS485 interface: 1 – not used 2 M24 24 V output ground, max. 0.2 A 3 RxD/TxD-P Receive/transmit data plus, B-line 4 – not used 5 DGND Data transmission potential (reference pot. for VP)6 VP Supply voltage plus (5 V) 7 P24 24 V output voltage plus 8 RxD/TxD-N Receive/transmit data N, A-line 9 – not used Design: 9-pin Sub-D female connector

MBP interface (non-intrinsically safe): 1 + 2 Shield 3 − 4 not used Design: 4-pin terminal strip. Observe the information regarding conductor section (see page 41).

Connection diagram

Modbus module Application Transfers measured values and status signals as well as analog inputs, digital inputs and digital outputs to host systems, e.g. to standard Windows applications via M-DDE Server; Modbus slave protocol in RTU (remote terminal unit) mode or via RS485 or RS232 interface (configurable).

Electrical connections RS232 interface: 2 RxD 3 TxD 5 GND Design: 9-pin Sub-D male connector

RS485 interface: 2 RTxD− 3 RTxD+ 5 GND Design: 9-pin Sub-D female connector

Connection diagram

1

6

RS485 MBP

1 2 3 4

1

6

1

6

RS232 RS485


Digital I/O module 4 digital inputs (DI1 to DI4) Optocouplers with internal DC 24 V power supply, jointly galvani-cally isolated from ground. Control with floating contacts, with external voltage DC 12 to 24 V or with open collector drivers PNP or NPN.

4 digital outputs (DO1 to DO4) Floating double-throw contacts, max. contact load rating DC 30 V/1 A, galvanically isolated from ground. Relays must at all times be operated within the specified data range. Inductive or capacitive loads are to be connected with suitable protective measures (self-induction recuperation diodes for inductive loads and series resistors for capacitive loads).

Standard function block applications Status signals, externally controlled calibration:

DO1 Failure/collective status DO2 Maintenance mode/limit value DO3 Maintenance request/limit value DO4 External solenoid valve DI1 Start automatic calibration DI2 Inhibit automatic calibration DI3 Calibrate zero-point DI4 Calibrate end-point

Measurement range control: DO1 Measurement range feedback DO2 Measurement range feedback DO3 Measurement range feedback DO4 Measurement range feedback DI1 Measurement range switchover DI2 Measurement range switchover DI3 Measurement range switchover DI4 Measurement range switchover

Limit values: DO1 Limit value DO2 Limit value DO3 Limit value DO4 Limit value DI1 Calibration cells in/out DI2 Hold current output DI3 Pump on/off DI4 External failure

Calibration control: DO1 External solenoid valve sample gas DO2 External solenoid valve zero gas DO3 External solenoid valve span gas DO4 External pump on/off DI1 Pump on/off DI2 External failure DI3 External failure DI4 External failure

Electrical connections See connection diagram Design: 2x12-pin terminal strip. Observe the information regard-ing conductor section (see page 41). The pin layout in a delivered gas analyzer will be shown in the ap-plicable “Analyzer data sheet”. Relays are shown in the unpowered state. The unpowered state is the failure mode.

Connection diagram

2

1 3 5 7 9 11 13 15 17 19 21 23

4 6 8 10 12 14 16 18 20 22 24

DI4 DO3 DO2 DO1DO4DI3 DI2 DI1

131517141618192123202224

DO4 NOCommonNC

DO3 NOCommonNC

DO2 NOCommonNC

DO1 NOCommonNC

123564789111210

max. 30 V / 1 A

max. 30 V / 1 A

max. 30 V / 1 A

max. 30 V / 1 A

DI4 -

DI3 -

DI2 -

DI1 -

+

+

+

+

GND

GND

GND

GND

24V

24V

24V

24V12-24 V

12-24 V

12-24 V

12-24 V


— … I/O modules

2-way analog output module 2 analog outputs (AO1, AO2) 0/4 to 20 mA (configurable, factory-set to 4 to 20 mA), common negative pole, galvanically isolated from ground, freely connecta-ble to ground, max. gain relative to protective ground potential 50 V, max. working resistance 750 Ω. Resolution 16 bit. The out-put signal cannot be lower than 0 mA.

Electrical connections See connection diagram Design: 4-pin terminal strip. Observe the information regarding conductor section (see page 41). The pin layout in a delivered gas analyzer will be shown in the ap-plicable “Analyzer data sheet”.

Connection diagram

4-way analog output module 4 analog outputs (AO1 to AO4) 0/4 to 20 mA (configurable, factory-set to 4 to 20 mA), common negative pole, galvanically isolated from ground, freely connecta-ble to ground, max. gain relative to protective ground potential 50 V, max. working resistance 750 Ω. Resolution 16 bit. The out-put signal cannot be lower than 0 mA.

Electrical connections See connection diagram Design: 8-pin terminal strip. Observe the information regarding conductor section (see page 41). The pin layout in a delivered gas analyzer will be shown in the ap-plicable “Analyzer data sheet”.

Connection diagram

4-way analog input module 4 analog inputs (AI1 to AI4) 0 to 20 mA into 50 Ω, jointly galvanically isolated from ground.

Current output DC 24 V for supply of an external sensor, fused with 100 mA (re-settable fuse)

Electrical connections See connection diagram Design: 2x5-pin terminal strip. Observe the information regarding conductor section (see page 41). The pin layout in a delivered gas analyzer will be shown in the ap-plicable “Analyzer data sheet”.

Connection diagram

1 2 3 4

1234

AO1 +-

AO2 +-

0/4 to 20 mA, max. 750

0/4 to 20 mA, max. 750

1 2 3 4 5 6 7 8

12345678

AO3

AO1

+

+

-

-

AO4

AO2

+

+

-

-

0/4 to 20 mA, max. 750

0/4 to 20 mA, max. 750

0/4 to 20 mA, max. 750

0/4 to 20 mA, max. 750

2 4 6 8 10

97531

123456789

10

50

50

50

50

AI1

AI3

I

I

C

C

AI2

AI4

I

I

C

C+24 VGND

0 to 20 mA into 50

0 to 20 mA into 50

0 to 20 mA into 50

0 to 20 mA into 50

external sensorPower supply for


— Dimensions

19-inch housing (model AO2020)

Dimensions in mm (in.)

Wall-mount housing (model AO2040)

Dimensions in mm (in.)

Notes The connection box is flanged to the housing in IP54 version. Take into consideration the space required for the connecting lines (approx. 100 mm/4 in.). 19-inch rack housing: For sufficient air circulation, multiple hous-ings in a 19-inch rack must be installed with a separation of at least one height unit between housings.

With an installed FID analyzer module with heated sample gas connection take into consideration the space required for the heated sample gas line corresponding to its minimum bending radius. Wall-mount housing: With an installed FID analyzer module, addi-tional clearance (approx. 300 mm/12 in.) is required since some assemblies can only be accessed from above.


— Certifications

Performance tests The AO2000 Series gas analyzers Uras26 (sample components CO, NO, SO2, CO2, N2O), Magnos206 (sample component O2) and electrochemical oxygen sensor (sample component O2) are certi-fied for use in facilities requiring approval according to European directives 2001/80/EG and 2000/76/EG and meet the require-ments of the 27th/30th BImSchV (German Federal Immissions Control Ordinance) and TA-Luft (German Technical Instructions on Air Quality) regulations. The requirements of QAL1 according to EN 15267 and EN 14181 are fulfilled. Report No. 821029 of June 30, 2006. Notification: Federal Gazette of October 14, 2006, No. 194, page 6715 Report No. 1249694 of March 30, 2009. Notification: Federal Gazette of August 25, 2009, No. 125, page 2932. Report No. 1710933 of September 30, 2011. Notification: Federal Gazette of March 2, 2012, No. 36, page 923. Report No. 936/21217137/A of October 14, 2011. Notification: Federal Gazette of March 2, 2012, No. 36, page 922. Report No. 1958844 of August 30, 2013, Notification: Federal Gazette AT of April 01, 2014, No. B12, page 15.

The AO2000 Series gas analyzers Uras26 (sample components CO, NO, NOx, SO2, N2O, CO2), Magnos206 (sample component O2), Magnos28 (sample component O2) and electrochemical oxygen sensor (sample component O2) meet the requirements of the „MCERTS Performance Standards for Continuous Emission Moni-toring Systems, Version 3.5 dated June 2016“, EN 15267-3:2007 and QAL 1 according to EN 14181:2014. Certificate No. Sira MC080121/13 of August 18, 2017

The AO2000 Series gas analyzers Limas21 UV (sample compo-nents NO, NO2, SO2) and electrochemical oxygen sensor (sample component O2) are certified for use in facilities requiring ap-proval according to European directives 2001/80/EG and 2000/76/EG and meet the requirements of the TA-Luft (German Technical Instructions on Air Quality) regulations. The require-ments of QAL1 according to EN 15267 and EN 14181 are fulfilled. Report No. 2231669.1 of September 1, 2015, Notification: Federal Gazette AT of March 14, 2016, No. B7, page 2. Certificate No. Sira MC160293/01 of May 04, 2016

The AO2000 Series gas analyzer Fidas24 (sample component C-total) is certified for use in facilities requiring approval (13th BImSchV, 17th BImSchV, 30th BImSchV, TA-Luft – German Technical Instructions on Air Quality) and in facilities of 27th BImSchV (German Federal Immissions Control Ordinance). The requirements of QAL1 according to EN 15267 and EN 14181 are fulfilled. Report No. 936/21228173/A of October 21, 2015, Notification: Federal Gazette AT of March 14, 2016, No. B7, page 2. Certificate No. Sira MC160292/02 of August 03, 2016

The AO2000 Series gas analyzer Uras26 (sample components SO2 und CO2) is certified for use on vessels. The requirements of MEPC.184(59) and MEPC.259(68), Chapter 6 “Emission Testing” as well as the relevant requirements of Revised MARPOL Annex VI and NOx Technical Code 2008 are fulfilled. Certificate No. 30652-15 HH of November 27, 2015

The AO2000 Series gas analyzer Limas21 UV (sample components NO, NO2 und NOx) is certified for use on vessels. The requirements of Revised MARPOL Annex VI and NOx Technical Code 2008 are fulfilled. Certificate No. 31812-16 HH of October 13, 2016

CE conformity The AO2000 Series gas analyzers satisfy the requirements of the European directives 2014/35/EU Low Voltage Directive, 2014/30/EU EMC Directive and 2014/34/EU ATEX Directive (explosion-protected versions only).

Approval for USA and Canada – CSA The AO2000 series gas analyzers are certified for use in general purpose environment, evidenced by full compliance with stand-ards CAN/CSA-C22.2 No. 61010-1-12 and UL Std. No. 61010-1 (Third Edition). Certificate No. 70012655

Approval for the customs union of Russia, Belarus and Kazakhstan – GOST TR CU The AO2000 Series gas analyzers are certified for use in general purpose environment. GOST TR CU certificate No. TC N RU Д-DE.AB72.B.02310 Pattern approval certificate for Russia No. DE.C.31.004.A No. 37985.


Explosion protection to European standards The AO2000 Series gas analyzers with Uras26, Magnos206, Caldos25 and Caldos27 in category 3G for measurement of flam-mable and non-flammable sample gas (“safety concept”) satisfy the European standards EN 60079-15:2010, EN 60079-2:2014, EN 60664-1:2007 Marking:

II 3G Ex nA pyb II T4 Gc

The AO2000 Series gas analyzers with Uras26, Magnos206, Magnos27, Caldos25 and Caldos27 in category 3G for measure-ment of non-flammable sample gas satisfy the European stand-ards EN 60079-15:2010, EN 60664-1:2007. Marking:

II 3G Ex nA nC IIC T4 Gc

The LS25 analyzer module for use in zone 2 satisfies the European standards EN 60079-0:2012 + A11:2013, EN 60079-15:2010, EN 60079-28:2015, EN 60079-31:2014. Marking:

II 3 G Ex nA nC [op is Ga] IIC T5 1) Gc, −20°C ≤ Tamb ≤ +55°C II 3 D Ex tc [op is Da] IIIC T100°C Dc, −20°C ≤ Tamb ≤ +55°C

1) T4 for special applications Type Examination Certificate No. Presafe 16 ATEX 8621X

Explosion protection to U.S. and Canadian standards – CSA The AO2000 Series gas analyzers with Uras26, Limas21 UV, Limas21 HW, Magnos206, Magnos28, Magnos27, Caldos25, Caldos27 und LS25 are certified for use in explosion hazard areas Class 1, Div. 2, Groups A, B, C, and D, Temperature code T4, ambi-ent temperature see page 39. Housing versions not equipped with conduit entries must be in-stalled in a suitable enclosure, cabinet or rack with provision for connection of Div. 2 wiring methods, acceptable to the local in-spection authority having jurisdiction. Certificate No. 1105720

Explosion protection for the customs union of Russia, Belarus and Kazakhstan – GOST TR CU The AO2000 Series gas analyzers in the “safety concept” version are certified for use in Zone 2 environment. Certificate No. TC RU C-DE.ГБ04.B.00278

Explosion protection for China – NEPSI The AO2000 series gas analyzers with Uras26, Magnos206, Caldos25 and Caldos27 are certified for use in hazardous loca-tions. The gas analyzers may be used for measurement of non-flammable gases and vapors. Marking: Ex nA nC IIC T4 Gc Certificate No. GYJ17.1139X

The AO2000 series gas analyzers with Uras26, Magnos206, Caldos25 and Caldos27 are certified for use in hazardous loca-tions. The gas analyzers may be used for measurement of flam-mable gases and vapors. Marking: Ex nA nC py IIC T4 Gc Certificate No. GYJ17.1140X

Explosion protection for South Korea – KCs The AO2000 Series gas analyzers with Uras26, Magnos206, Caldos25 and Caldos27 are certified for use in hazardous loca-tions. They may be used for measurement of flammable gases and vapors. Marking: Ex nA py II T4 Certificate No. 16-GA4BO-0670X Sales Service


— Sample components and analyzer modules The following table lists the sample components that can be measured with the AO2000 Series gas analyzers (other sample components available on request).

In each case, the smallest measurement range and the appropri-ate analyzer module are given. Please see the data of the individ-ual analyzer modules.

Sample component Requirements (examples) Smallest meas. range Analyzer module Data

Acetylene C2H2 Small meas. ranges, selective measurement 0–100 ppm Uras26 Page 6

Ammonia NH3 Process measurement 0–30 ppm Uras26 Page 6

Combustion exhaust gas 0–100 ppm Limas21 HW Page 10

Argon Ar in N2 Especially short T90 time 97.5–100 vol.% Caldos27 Page 24

Ar in O2 Especially short T90 time 0–2 vol.% Caldos27 Page 24

Butane C4H10 Small meas. ranges, selective measurement 0–50 ppm Uras26 Page 6

Chlorine Cl2 Corrosive gases 0–100 ppm Limas21 UV Page 8

Nitrous oxide N2O Small measurement ranges 0–20 ppm Uras26 Page 6

Ethane C2H6 Small meas. ranges, selective measurement 0–50 ppm Uras26 Page 6

Ethylene C2H4 Small meas. ranges, selective measurement 0–300 ppm Uras26 Page 6

Helium He in N2 Especially short T90 time 97–100 vol.% Caldos27 Page 24

Hexane C6H14 Selective measurement 0–100 ppm Uras26 Page 6

Refrigerant R 134a Small measurement ranges 0–50 ppm Uras26 Page 6

Carbon dioxide CO2 Small measurement ranges 0–5 ppm Uras26 Page 6

CO2 in N2 or air Especially short T90 time 0–3 vol.% Caldos27 Page 24

Carbon disulfide CS2 Toxic/flammable gases 0–50 ppm Limas21 UV Page 8

Carbon monoxide CO Small meas. ranges, emission measurement 0–10 ppm Uras26 Page 6

Carbon oxide sulfide COS Toxic/flammable gases 0–250 ppm Limas21 UV Page 8

Hydrocarbons Total Fast hot measurement 0–5 mg C/m3 Fidas24 Page 26

CnHm − CH4 Non-methane measurement 0–5 mg C/m3 Fidas24 NMHC Page 28

Methane CH4 Small meas. ranges, selective measurement 0–50 ppm Uras26 Page 6

CH4 in N2 Especially short T90 time 99–100 vol.% Caldos27 Page 24

CH4 in N2 or air Especially short T90 time 0–2 vol.% Caldos27 Page 24

Propane C3H8 Small meas. ranges, selective measurement 0–50 ppm Uras26 Page 6

Propylene C3H6 Small meas. ranges, selective measurement 0–100 ppm Uras26 Page 6

Oxygen O2 Magnetomechanical measurement principle 0–0.5 vol.% Magnos206 Page 14

Magnetomechanical measurement principle 0–0.5 vol.% Magnos28 Page 16

Trace measurement with ZrO2 cell 0–1 ppm ZO23 Page 20

Electrochemical measurement principle 0–5 vol.% Oxygen sensor Page 34

O2 in N2 Thermomagnetic measurement principle 0–3 vol.% Magnos27 Page 18

O2 in flue gas Thermomagnetic measurement principle 0–3 vol.% Magnos27 Page 18

Sulfur dioxide SO2 Emission measurement 0–25 ppm Uras26 Page 6

Corrosive gases 0–25 ppm Limas21 UV Page 8

SO2 in N2 or air Corrosive gases 0–1.5 vol.% Caldos25 Page 22

Hydrogen sulfide H2S Exhaust gas, process measurement 0–25 ppm Limas21 UV Page 8

Nitrogen dioxide NO2 Corrosive gases 0–50 ppm Limas21 UV Page 8


Nitrogen monoxide NO Emission measurement 0–75 ppm Uras26 Page 6

Small measurement ranges 0–10 ppm Limas21 UV Page 8


Hydrogen H2 in Ar Especially short T90 time 0–0.25 vol.% Caldos27 Page 24

H2 in Cl2 Corrosive gases 0–0.5 vol.% Caldos25 Page 22

H2 in stack gas Especially short T90 time 0–0.5 vol.% Caldos27 Page 24

H2 in N2 Especially short T90 time 99–100 vol.% Caldos27 Page 24

H2 in N2 or air Corrosive gases 0–0.5 vol.% Caldos25 Page 22

Especially short T90 time 0–0.3 vol.% Caldos27 Page 24


— Notes


— … Notes

— ABB Automation GmbH Measurement & Analytics Stierstädter Str. 5 60488 Frankfurt am Main Germany Fax: +49 69 7930-4566 Mail: [email protected]

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